Sr.

Number:OISD/DOC/2016/1
Page No. I

OISD-STANDARD-235
FOR RESTRICTEDCIRCULATION ONLY

STORAGE, HANDLING, REFUELLING AND FIRE FIGHTING AT

AVIATION FUELLING STATIONS

Prepared by

FUNCTIONAL COMMITTEE

First Edition, January 2015

OIL INDUSTRY SAFETY DIRECTORATE

GOVERNMENT OF INDIA
MINISTRY OF PETROLEUM AND NATURAL GAS
8th Floor, Tower-A, OIDB Bhawan
Plot No: 2, Sector-73
NOIDA - 201301 Uttar Pradesh, India
Website: -www.oisd.gov.in
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Preamble
Indian petroleum industry is the energy lifeline of the nation and its continuous performance
is essential for sovereignty and prosperity of the country. As the industry essentially deals
with inherently inflammable substances throughout its value chain – upstream, midstream
and downstream – Safety is of paramount importance to this industry as only safe
performance at all times can ensure optimum ROI of these national assets and resources
including sustainability.

While statutory organizations were in place all along to oversee safety aspects of Indian
petroleum industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of
Petroleum and Natural Gas, Government of India as a knowledge centre for formulation of
constantly updated world-scale standards for design, layout and operation of various
equipment, facility and activities involved in this industry. Moreover, OISD was also given
responsibility of monitoring implementation status of these standards through safety audits.

In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative
and participative process of development of standards – starting with research by in-house
experts and iterating through seeking & validating inputs from all stake-holders – operators,
designers, national level knowledge authorities and public at large – with a feedback loop of
constant updation based on ground level experience obtained through audits, incident
analysis and environment scanning.

The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry culminating in a safer environment in the industry. OISD –
except in the Upstream Petroleum Sector – is still a regulatory (and not a statutory) body but
that has not affected implementation of the OISD standards. It also goes to prove the old
adage that self-regulation is the best regulation. The quality and relevance of OISD
standards had been further endorsed by their adoption in various statutory rules of the land.

Petroleum industry in India is significantly globalized at present in terms of technology

content requiring its operation to keep pace with the relevant world scale standards &
practices. This matches the OISD philosophy of continuous improvement keeping pace with
the global developments in its target environment. To this end, OISD keeps track of changes
through participation as member in large number of International and national level
Knowledge Organizations – both in the field of standard development and implementation &
monitoring in addition to updation of internal knowledge base through continuous research
and application surveillance, thereby ensuring that this OISD Standard, along with all other
extant ones, remains relevant, updated and effective on a real time basis in the applicable
areas.

Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This,
besides other issues, calls for total engagement from all levels of the stake holder
organizations, which we, at OISD, fervently look forward to.

Jai Hind!!!
Executive Director
Oil Industry Safety Directorate
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NOTE

Oil Industry Safety Directorate (OISD) publications are prepared for use in the oil and
gas industry under Ministry of Petroleum & Natural Gas. These are the property of
The Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and
loaned or exhibited to others without written consent from OISD.

Though every effort has been made to ensure the accuracy and reliability of the data
contained in these documents, OISD hereby disclaims any liability or responsibility
for loss or damage resulting from their use.

These documents are intended to supplement rather than replace the prevailing
statutory requirements.
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FOREWORD

At the time of development of this document, 113 Codes and Standards,

Recommended Practices and guidelines of OISD are applicable to the oil and gas
installations of Public sector oil companies in India. 11 of these standards have been
adopted by Petroleum and Explosives Safety Organisation (PESO) in various rules
administered by them and thus the provisions of these standards are mandatory for
entire Oil & Gas sector to that extent.

During 48th Steering committee meeting of Oil Industry Safety directorate (OISD),
industry members decided to develop a comprehensive new standard covering all
the facets of Safety in STORAGE, HANDLING, REFUELLING AND FIRE FIGHTING at
Aviation Fuelling Stations.

This document on “STORAGE, HANDLING , REFUELLING AND FIRE FIGHTING AT

AVIATION FUELLING STATIONS ” has been prepared by the functional committee
based on existing national standards, guidelines and recommended practices of
OISD, the recommendations arising out of accumulated knowledge and experience
of industry members and international codes & practices.

This document will be reviewed periodically for improvements based on the new
experiences and updation in national & international standards and practices.
Suggestions may be addressed to:

The Coordinator,
Committee on “AFS”
Oil Industry Safety Directorate,
8th Floor, Tower-A, OIDB Bhawan
Plot No: 2, Sector-73
NOIDA - 201301 Uttar Pradesh, India
Website:- www.oisd.gov.in
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FUNCTIONAL COMMITTEE

Name Organization
LEADER
Sh. Sanjay Chauhan Reliance Industries Limited
MEMBERS

Sh. Amitava Bose Indian Oil Corporation Limited

Sh. B.K.Singh Bharat Petroleum Corporation Ltd., Mumbai

Sh. S. Manivannan Bharat Petroleum Corporation Ltd., Mumbai

Sh. Rajendra Thikekar Hindustan Petroleum Corporation Limited

MEMBER COORDINATOR
Oil Industry Safety Directorate, New Delhi
Sh. U S Roy
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CONTENTS
SR. No ITEM PAGE No
1 Introduction 1
2 Scope 1
3 Definitions 2
4 Statutory Rules/ Regulations 8
5 Hazardous Area Classification 8
6 Layout Design
6.1 Design philosophy 10
6.2 Layout of facilities 11
6.3 General consideration for the layout of the facility 11
6.4 Layout of storage tanks
Table-1 16
Table-2 18
Table-3 19
7 Design Considerations
7.1 Types of storage tanks 21
7.2 Selection of type of storage tanks 21
7.3 Special Considerations 21
7.4 Tank appurtenances 21
7.5 Tank farms/manifolds 22
7.6 Drains/Sampling points 23
7.7 Vents 23
7.8 Dip Hatch/Sampling 23
7.9 Instrumentation 23
7.10 Piping/valves/flanges 24
7.11 Bulk Loading /unloading operations 25
7.12 Handling of Slop 26
7.13 Electrical equipment 26
7.14 AFS Lighting 30
8 Safe Operating Practices in Storage and handling of bulk
petroleum products
8.1 General 31
8.2 Safe Operating Practices. 31
8.3 Bulk Handling for Movement by Road 32
8.4 Safety Precautions during TT/Refuellers Loading / Unloading 32
8.5 Procedures for Operation 33
8.6 Pipeline Transfer Operations 34
8.7 Tank farm Operations Safety Precautions in Tank Farm Area 35
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8.8 Methanol Handling at AFS 35

8.9 Refuelling operations 36
8.10 Safety in design of HRS 44
8.11 Safety in Aircraft Refuelling Operations 44
8.12 Safety feature in Hydrant Refuelling System 46
8.13 Safety in Barrel operations 48
9 Fire Protection Facilities
9.1 General Considerations 50
9.2 Fire protection Philosophy 50
9.2.1 Fire Protection 50
9.2.2 Design Criteria for Fire Protection System for AFS with more than 50
1000KL Above Ground Tanks
9.3 Fire Fighting Facilities at AFSs 52
10 Combined POL and LPG Facilities in the Same Premises 55
11 Fire Water System Design 54
11.1 Fire Water Design Flow Rate 55
11.2 Fire Water Storage 55
11.3 Fire Water Pumps 55
11.4 Fire Hydrant Network 56
11.4.1 Hydrant/Monitors 59
11.4.2 Material Specifications 59
11.4.3 Fixed Water Spray System 60
11.4.4 Foam Systems 60
11.4.5 Conveying Systems of Foam 62
11.4.6 Foam Protection 63
11.4.7 Foam Application 64
11.4.8 SCADA/Server Room Protection 65
11.4.9 First Aid Fire Fighting Equipment 65
11.5 Emergency Shut Down Logic for Automation System. 65
11.6 Fire Safety Organisation/ Training 66
11.7 Disaster Control Management Plan 67
11.8 Fire Protection System, Inspection and Testing 67
12 Maintenance & Inspection of Equipments 69
13 Management of Change 73
14 Emergency Preparedness Plan and Response 75
15 Training ( including contract workmen ) 83
16 Safety Inspection/Audit 83
17 Annexures
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Annexure- 1. Critical Alarm Levels in Tank 87

Annexure- 2. Checklist for Bulk ATF Tank Trucks at AFSs 88
Annexure- 3. Maintenance Schedule of Critical Equipment (Pumps& Diesel 89
Engines)
Annexure- 4. Format for Request for Management of Change (MOC) 91
Annexure- 5. Delegation of Authority (DOA) for MOC: Aviation Fuel Stations 93
Annexure- 6. Safety Check Lists 97
Annexure- 7. Check list for Electrical Audits 99
Annexure- 8. External Safety Audit Check List 108
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STORAGE, HANDLING, REFUELLING AND FIRE FIGHTING AT AVIATION
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1.0 INTRODUCTION

The Aviation Fuelling Stations (AFS) / Aviation Service Facilities (ASF) are generally located at
the airports or near to the airport for both defence and civil categories.

In view of high growth in aviation sector in India, a need was felt to consolidate and develop a
comprehensive standard covering all aspects including design, operation, maintenance and safety in
receipt, storage, handling, refuelling and firefighting of aviation fuels at AFS. The requirement of a
safety system is to prevent emergencies from developing into major threat to the AFS and
surroundings including the airport.

2.0 SCOPE

2.1 This standard lays down the minimum safety requirements in design, layout, fire protection,
storage, loading and unloading operation, refuelling operation, mobile refuelling equipment,
hydrant refuelling system, handling, storage and supply of Aviation products in barrels/packed
conditions, inspection & maintenance, training, emergency plan & response, and safety audit
systems of AFS.

2.2 This standard does not cover:-

a) The intermediate depot, terminals and refineries handling aviation fuels for which relevant OISD
standards to be referred (OISD-STD-118, OISD-STD-117, OISD-STD-116 etc.) for layout and fire
protection facilities.

b) Firefighting facilities of ports handling hydrocarbons including aviation fuels for which OISD-STD-
156 shall be referred.

c) The facilities on cross-country pipelines (including aviation fuels) that include sectionalizing valve
station, pig launching / receiving station, intermediate pumping station, dispatch and receiving
facilities withoutabove ground storage for which OISD-STD-141 shall be referred.

d) Quality control aspects of aviation fuels.

2.3 Keeping in view paucity of land for AFS and availibility of a reliable fire fighting support from the
airport operator , the provisions of this standard shall be applicable to all new upcoming AFSs.
Inter distance norms as defined in this standard will not be mandatory for existing facilities,
equipment, structures that are already in place ie. are installed before the date of publication of
this Standard.The requisite inter-distance norms will also not be mandatory for augmentated
facility in existng AFS, which is necessitated due to increased demand at the airport.

2.4 The portable fire protection facilities given in this standard shall be aplicable to existing and new
upcoming AFS , including augmentation of existing facilities of AFS. Fixed fire protection facilities
shall be provided in this standard for new facilties only. For existing AFSs and its augmentation,
the same should be provided to the extent possible.

2.5 Requirement of green belt /buffer zone beyond the AFS boundary is outside the scope of this
standard.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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3.0 DEFINITIONS :

I Clean agent
Electrically nonconductive, volatile or gaseous fire extinguishant that does not leave
a residue upon evaporation and meets the requirements given in the latest NFPA 2001 on clean
agent fireextinguishing systems in line with environmental considerations of Kyoto and Montreal
Protocol & latest MOEF (Ministry of Environment & Forest) regulations.

II. AFS SCADA/Server room

The room is an enclosure, equipped with control, monitoring and
communication systems used for handling and operation of aviation fuels with automated hydrant
refuelling system. This room can be located inside an administrative building.

III. Explosive mixture

It is a mixture of combustion agent (oxidising product gas, vapour, liquid or solid) and a fuel
(oxidisable product - gas, liquid or solid) in such proportions that it could give rise to a very rapid and
lively oxidization reaction liberating more energy than is dissipated through conduction and
convection.

IV. Lower explosive Limit (LEL)

Is the minimum concentration of a vapour in air (or other oxidant) below which propagation of flame
does not occur on contact with an ignition source. This is usually expressed as volume percentage of
the vapour in air. This is also referred as Lower Explosive Limit (LEL).

V. Upper Explosive Limit (UEL)

Is the maximum concentration of a vapour in air (or other oxidant) above which propagation of flame
does not occur on contact with an ignition source.This is usually expressed as a volume percentage
of vapours in air. This is also referred as Upper Explosive Limit (UEL)

VI. Flammable Liquid

It is a liquid capable of producing a flammable vapour or mist under any foreseeable operating
conditions.

VII. Flammable Mist

Droplets of flammable liquid, dispersed in air, so as to form an explosive atmosphere.

VIII. Earthing

Earthing is the provision of a safe path of electrical current to ground, in order to protect structures,
plant and equipment from the effects of stray electrical current, and electrostatics discharge.

IX. Earth Electrode

A metal plate, pipe or other conductor embedded in the soil that makes a direct contact to the general
mass of the earth.

X. Earth Connection

A connection to general mass of earth by means of earth grid and /or earth electrode. An object is
said to be ‘earthed’ when it is electrically connected to earth grid and/or earth electrode, and a
conductor is said to be ‘solidly earthed’when in it electrically connected to earth electrode witout a
fuse , switch, circuit breaker, intentional resistance or impedance in the earth connection.

XI. Bonding

Bonding is the process by which two electrical conducting bodies are connected using a conductor to
maintain electrical continuity to prevent sparking.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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XII. Facility

This refers to any building, structure, equipment, pipeline or any other physical feature used in AFS
for handling of aviation fuels at various stages of operations, fire protection, testing, maintenance,
security, utilities services, mobile equipment and communication etc.

XIII. Flameproof (Ex-d)-(Ref:IS: 2148)

An enclosure for electrical apparatus that will withstand, when the covers or other access doors are
properly secured, an internal explosion of the flammable gas or vapour which may enter it or which
may originate inside the enclosure, without suffering damage and without communicating the internal
flammation to the external.

XIV. Intrinsically Safe

A circuit or part of a circuit is intrinsically safe when any spark or thermal effect produced normally
(that is, by breaking or closing the circuit) or accidentally (for example, by short circuit or earth fault) is
incapable, under prescribed test conditions, of causing ignition of a prescribed gas or vapour. An
intrinsically safe apparatus is one in which all electrical circuits are intrinsically safe. (For details, IS:
5780 shall be referred)

XV. Flash Point

"Flash point" of any petroleum liquid is the lowest temperature at which the liquid yields vapour in
sufficient concentration to form an ignitable mixture with air and gives a momentary flash on
application of a small pilot flame under specified conditions of test as per IS: 1448 (Part-I).

XVI. General Classification of Petroleum Products

Petroleum products are classified according to their closed cup Flash Point as given below:

Class-A Petroleum: Liquids which have flash point below 23 degree C.

Class-B Petroleum: Liquids which have flash point of 23 degree C and above but below 65 degree C.

Class-C Petroleum: Liquids which have flash point of 65 degree C and above but below 93 degree C.

Excluded Petroleum:Liquids which have flash point of 93 degree C and above.

Liquefied gases including LPG do not fall under this classification but form separate category.

Note: In the following cases, above classification do not apply and special precautions should be
taken as required:

(i) Where ambient temperatures or the handling temperatures are higher than the flash point of the
product.

(ii) Where product handled is artificially heated to a temperature above its flash point.

XVII. Aviation Turbine Fuel (ATF)

There are basically two types of aviation fuels viz. Jet A1 (K-50) as per IS-1571, RT fuel (K-60) and
JP5 are all Class B POL products. These kerosene type aviation fuels have minimum flash point of
38 degrees C (for Jet A1),28 degrees C (for K-60) and 60 degree C for JP5. At ambient temperatures
they must be treated as flammable liquids and additional precautions should always be taken in
handling them at these temperatures.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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XVIII. Aviation Gasolene 100 Low Lead (Avgas100LL):

Avgas 100LL (IS 1604) is a Class A product and is dyed blue. The product is used for small aircrafts
with piston type engines.

XIX. Fire Safe

As applied to valves, it is the concept of controlling the leakage to an acceptable level, after damage
encountered during and after the fire, achieved by dual seating.

XX. Fire Station

Building/ housing facilities for parking fire tenders and keeping in readiness other fire-fighting
equipment for meeting plant emergencies, fire control room with required communication
facilities/mimic panel.

XXI. Fire Water pump house

A structure housing fire engines, fire water pumps, fire water jockey pumps, communication, alarm
system, instrumentation and other supporting equipment.

XXII. Aircraft refuelling

Delivery of aviation fuel to the aircraftsfrom the refuelling equipment. The refuelling equipment
isdesigned to ensure that fuel is delivered in a safe manner to the aircraft at the required pressure and
flow rate.

Depending on the scale of operation at an airport, the fuelling methods used are - mobile refuellers,
fuel hydrant systems, fuelling cabinet or barrel refuelling. Mobile Refuelling equipment are either
refuellersor hydrant dispensers.

a.Refuellers / Bowsers :Mechanically propelled vehicles with storage tank (rigid , semi-trailer or full
trailer) for aviation fuel, filtration, pressure control system, metering device and associated safety and
quality control system for transferring fuel into or from the aircraft.

b.Hydrant Dispensers: Self-propelled or towed trailer equipped with filters, meters , hoses and
controls that is used to transfer aviation fuel between a fuel hydrant and an aircraft.

c.Fuelling cabinet: A fixed above ground structure with hose , meters and auxiliary equipment from
which aviation fuel can be dispensed into an aircraft without any additional equipment.

XXIII. Aircraft defueling:

Transfer of aviation fuel from the aircraft to the refuelling equipment

XXIV. Hazardous Area

An area in which an explosive gas atmosphere is present, or likely to be present, in quantities such as
to require special precautions for the construction, installation and use of electrical apparatus.

XXV. Non- Hazardous area

An area in which an explosive gas atmosphere is not expected to be present in quantities such as to
require special precautions for the construction, installation and use of electrical apparatus.

XXVI. Incident

An unplanned event (occurrence, conditionor action) which did or couldhave resulted in personal
injury or damage to the plant,community or environment.

XXVII. Near-miss

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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An incident which does not result in any injury or damage to property but has the potential to resultin
injury and / or property damage.

XXVIII. GPM

Denotes US gallons (1GPM=3.785 lpm)

XXIX. Kerb wall

A wall of appropriate height and size constructed of suitable material and designed to contain the Oil
spillage and to direct it to ETP/OWS.

XXX. Aviation Fuel Station (AFS)

The facilities for receipt of aviation fuel through tank trucks or/and pipelines, storage tanks in
bulk,pumps, piping and associated equipment like filters, fuel hydrants etc, and refuelling of aircrafts
through refuellers, hydrant dispensers and fuelling cabinets.It also include facilities for storage of
methanol & Avgas 100LL in barrels, aviation lubricants, HSD(for own consumption) and other
additives in packed condition.

XXXI. Sample Room / Additive storage/ DP shed:

Building for storing retention samples, packed additives,Power boost Methanol, Aviation gasoline 100
LL, flammable materials etc.

XXXII. Service Building

Building/structure housing facilities for inspection/maintenance/other supporting services which are

directly required for operation of the AFS.

XXXIII. Hydrant Refuelling System

A type of fixed refuelling system that includes an underground system of pipes and valves used to
transfer aviation fuel directly from fuel storage facility to one or more designated aircraft parking
positions. This also includes pumps, filters and controls which are usually located at the AFS.

a.Hydrant pit valves: Mechanism connected to the termination point of the each lateral or riser of
underground fuel hydrant pipe to allow fuel to flow from the hydrant refuelling pipeline system to the
aircraft by connecting a coupler to a hose installed on hydrant dispenser. These valves shall conform
to EI 1584.

b.Hydrant pit: A chamber embedded in the apron that contains hydrant pit valve and conforming to
EI 1584.

XXXIV. ELECTRICAL SUB STATION

Electrical substation means any premises or enclosures / building or part thereof, being large enough
to admit the entrance of a person after the apparatus therein is in position, and housing any one or
more of the following equipment:

a. Apparatus for transforming or converting energy to or from a voltage.

b. Diesel Generating Set

c. Apparatus for distribution viz. MCC etc.

d. Any other apparatus for switching, controlling or otherwise regulating the energy.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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XXXV. Low Voltage (LV)

The voltage which does not normally exceed 250 volts.

XXXVI. Medium Voltage (MV)

The voltage which normally exceeds 250 volts but does not exceed 650 volts.

XXXVII. High Voltage (HV)

The voltage which normally exceeds 650 volts but does not exceed 33 KV.

XXXVIII. Slop

Off-specification/downgradedAviation Turbine Fuel or Avgas , during operations and draining etc.

from various equipment / tanks / pumps/ filters containing oil -water mixture are called slops.

XXXIX. Oil water separator (OWS)

Oil water separator is a system designed to separate gross amount of oil and suspended solids from
the oily water effluent generated due to different activities/operations in AFS.

XL. Risk Analysis / Assessment

Risk Analysis means the identification of undesired events that lead to the materialization of a hazard,
the analysis of the mechanisms by which these undesired events could occur and, usually, the
estimation of the extent, magnitude, and likelihood of any harmful effects.

Risk Assessment means the quantitative evaluation of the likelihood of undesired events and the
likelihood of harm or damage being caused by them, together with the value judgments made
concerning the significance of the results;

A variety of scenario analysis tools such as hazard and operability study (HAZOP) and Hazards
Analysis (HAZAN) are used for fire scenario analysis.

XLI. HAZOP
A Hazard and Operability (HAZOP) study is structured and systematic examination of process and
operation of a facility by applying a set of “Guide Words” in order to identify and evaluate safety and
operability problem that may pose risk to personnel or equipment, or prevent efficient operation.

XLII. HAZAN
Hazard Analysis (HAZAN) is simply the application of numerical methods to obtain an understanding
of hazards in terms of:

i. How often a hazard will manifest itself

ii. With what consequences for people, process and plant.

XLIII. Tanks

Storage tanks are defined as "ATMOSPHERIC PRESSURE STORAGE TANK".

Atmospheric pressure storage tank

Vertical Tanks are designed as per API STD 650 or equivalents IS standards, and horizontal storage
tanks (buried or semi-buried) as per IS 10987 or equivalent industry standards are called
ATMOSPHERIC PRSSSURE STORAGE TANKS. These tanks are designed to operate in its gas and
vapour spaces at internal pressure approximately equal to atmospheric pressure.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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These tanks are fitted with open vent to atmosphere.

XLIV. Tank height

Tank height is the height from tank bottom to top of the kerb angle for cone roof above ground tanks.
For horizontal buried, semi-buried and above ground tanks, it is equivalent to the outer diameter of
the tank.

XLV. Tank capacity

a. Nominal Capacity of a Tank

Nominal capacity shall mean the geometric volume of the tank from bottom up to Kerb angle in case
of fixed roof above ground vertical tanks,and is equal to the geometric volume for horizontal tanks.

b. Overfill Level (Nominal Capacity)

The maximum fill level of product within a tank as measured from the gauging reference point (that is,
striker plate) above which any additional product will overfill and spill out of the tank; or at which level,
contact or damage will occur to the tank structure or appurtenances

c. Normal Fill Level (Normal Capacity)

The level up to which the tank is allowed to receive product at the maximum allowable receiving flow
rate for a predetermined time prior to reaching the safe fill level.

d. Safe Capacity of a Tank

Safe Capacity (stored volume) is the capacity of the tank up to the maximum safe filling height (safe
filling level) of the tank as per PESO / statutory requirements.

The safe fill level is established by determining the amount of time required to take the appropriate
action necessary to completely shut down or divert product flow before the level of product in the tank
reaches the overfill level. The safe fill level shall be established for each specific tank that will depend
on the type of tank, diameter, its internal configuration and condition, rate of filling and the operating
practices.

e. Aggregate capacity

Combined safe capacity of storage tanks in an AFS.

f. Pumpable Capacity (Net Capacity)

Pumpable capacity (Net Capacity) is the capacity of the tank during operation after subtracting the
volume of tank bottom contents up to the top of pump out nozzle from safe filling capacity of the tank.

XLVI. Tank Trucks / Refuellers loading / unloading:

Facility for loading / unloading of ATF to / from tank truck/refuellers.

XLVII. Utilities:

Utilities consisting of administrative building, QC laboratory, canteen, parking shed, air

compressor,maintenance shed, security cabin, store etc. shall be away from other AFS facilities
located as per the inter-distance specified in this standard.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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XLVIII. Shall
Indicates provisions that are mandatory.

XLIX. Should
Indicates provisions that are recommended as good engineering practice but are not mandatory.

4.0 STATUTORY ACTS AND RULES

The Aviation Fuelling Station&its various facilities are covered under various regulations and require
specific approval / licence from concerned statutory authorities. The list of statutory acts, rules,
regulations inter-alia the following:

i. The Factories Rules made under The Factories Act, 1948.

ii. The Petroleum Rules, 2002 (Amended in the year 2011) made under the Petroleum Act,
1934.

iii. The Petroleum and Natural Gas Regulatory Board (PNGRB) Act, 2006.

iv. Civil Aviation Requirements (CAR) Series E&H issued by DGCA.

v. Central Electricity Authority (CEA) Safety Regulations, 2010 made under Indian Electricity
Act.

vi. The Standards of Weight & Measures Rules –1987 made under The Weight & Measures Act
1976.

vii. The Standards of Weight & Measures (Packaged Commodities Rules-1977).

viii. The Motor Vehicles (Central) Rules, 1989 made under the Motor Vehicles Act - 1988.

ix. Environmental Regulations made under the Environment (Protection) Act–1986.

x. The Water (Prevention & Control of Pollution) Act, 1974 and the Rules made there under.

xi. The Air (Prevention & Control of Pollution) Act- 1981 and the Rules made thereunder.

xii. Manufacture, Storage &Import of Hazardous Chemicals Rules – 1989 (latest edition).

xiii. Hazardous Waste (Management, Handling and Trans-boundary Movement) Rules, 2009.

xiv. Disaster Management Act, 2005.

xv. The Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996.

xvi. Environmental Protection Rules, 1986.

xvii. Environmental Impact Assessment Notification-2006.

5.0 HAZARDOUS AREA CLASSIFICATION

The hazardous area is mainly defined for the purpose of selection and installation of electrical
equipment, however definition shall be applied, as specified hereinafter , for other purposes also.

An area will be deemed to be hazardous where;

i. Petroleum having flash point below 65 deg.C or any flammable gas or vapour in a concentration
capable of ignition is likely to be present.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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ii. Petroleum or any flammable liquid having flash point above 65 deg.C is likely to be refined
blended,handled or stored at or above its flash point.

Classification of Hazardous area (for the purpose of selection and installation of electrical equipment):
A hazardous area shall be deemed to be-

i. Zone 0 - An area in which a flammable atmosphere is present continuously or is likely to be

present for long periods. Examples are vapour space above closed process vessels, storage
tanks or closed containers, areas containing open tanks of volatile, flammable liquids etc.

ii. Zone 1 - Area in which an explosive gas/mixture is likely to occur in normal operation. Zone-1
locations may be distinguished when any of the following conditions exist:

1. Flammable gas or vapour concentration is likely to exist in the air under normal operating
conditions.

2. Flammable atmospheric concentration is likely to occur frequently because of

maintenance, repairs orleakage.

3. Failure of process, storage or other equipment is likely to cause an electrical system failure
simultaneously with the release of flammable gas or liquid.

4. Flammable liquid or vapour piping system containing valves, meters, screwed or flanged
fittings arein an inadequately ventilated area.

5. The area below the surrounding elevation or grade is such that flammable liquids or
vapours mayaccumulate therein.

The zone-1 classification typically includes:

a. Inadequately ventilated ATF pump houses.

b. Interiors of Sample Retention Room/ DP shed
c. API Separators / OWS
d. Oily waste water sewer, basins, sampling/drain points/pits and hydrant pits.
e. Areas in the immediate vicinity of vents, floating suction inspection and manual
gauging hatch and filling hatches.
f. Unloading/loading points, proving measure.

g. Areas in which an explosive gas/air mixture is not likely to occur in normal operation and if it
occurs it will exist only for a short time like fast flushing system, sampling points

Zone-2 locations may be distinguished when any one of the following conditions exists:

a.The system handling flammable liquid or vapour is in an adequately ventilated area and is so
designed and operated that the explosive or ignitable liquids, vapours or gases will normally be
confined within closed containers or closed systems from which they can escape only during
abnormal conditions such as accidental failure of a gasket or packing.

b. The flammable vapours can be conducted to the location as through trenches, pipes or
ducts.

c. Locations adjacent to Zone-1 areas.

d. In case positive mechanical ventilation is used, the failure or abnormal operation of

ventilating equipment can permit atmospheric vapour mixtures to build up to flammable
concentrations.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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6.0 LAYOUT DESIGN

6.1 Design philosophy

Following philosophy should be adopted in layout of an AFS:

1) Identify and size the facilities needed for receipt, storage and delivery of Class B (ATF) in
bulk, based on the business & process requirements and with a provision for future
expansion. Facilities for receipt, storage and dispending of Class A (Av gas) shall be
designed and segregated from ATF.

2) Physical segregation/demarcation of hazardous and non-hazardous areas shall be provided.

Layout drawingindicating hazardous and non-hazardous area segregation /demarcation shall
be available.Hazardous area segregation/demarcation shall be as per BIS 5572:2009& OISD
-113.

3) These facilities will be located in the allotted plot of land based on the following :

i. De-licensed area consisting of admin building, security cabin, utilities will be nearer to the
entry/ exit gates to minimise movement of personnel in licensed premise.
ii. TT unloading/refuellers loading area and refuellers parking to be located in such a way that
vehicular movement is minimised.
iii. Facilities should be laid such that length of drain leading to OWS is minimal.

4) Risk Analysis / Assessment shall be carried out at the layout stage with an objective to arrive at
any specific mitigation measures required for the Hazards identified. Risk reduction / mitigation
measures shall be given due credit.

The outcome of risk assessment shall guide in preparation of onsite& off site emergency plan.

QuantitativeRisk Assessment (QRA) shall be done when ever major addition(s) in facilities or
major changes in the surrounding areas, operating parameters,product grade takes placeor
once in every five years whichever is earlier.

5) Minimum two approaches from the major road should be provided, one for for normal
movement and another for emergency exit.Both these approaches should be available for
receipt of assistance in emergency.

6) Roads inside the hazardous area of an AFS shall be restricted to vehicles required for
operational, maintenance and safety/security reasons and areto be allowed only with proper
safety fittings and authorization from location in-charge/designated safety officer.

7) Road widths, gradient and turning radii at road junctions shall be designed to facilitate
movement of the largest fire-fighting vehicle envisaged in the event of emergency.

8) Layout should consider the space requirements for :

i. Maintenance and inspection of each equipment / facility.

ii. Dedicated area for construction activities.

iii. Future expansion for addition of facilities.

iv. Parking of refuellers/hydrant dispensers and other vehicles.

9) Vehicles with spark ignition engine shall not be allowed inside hazardous area. Vehicles with
internal combustion engine (compression ignition)such as refuellers and tank truck required to

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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be permitted for business shall have Petroleum and Explosives Safety Organization (PESO)
approved spark arrestor fitted on the vehicle in line with PESO requirement.

10) The maximum height of structure at the AFS shall not exceed the maximum permissible height
specified by the local airport authority/operator.

6.2 Layout of facilities

To prepare a layout, information should be collected on all applicable aspects and not limiting to
following:

a. Storage tanks, utility requirements

b. Product receipt / dispatch and mode of transport (by Road & Pipeline)

c. Warehouses, DP Shed (for storing Avgas 100ll or Methanol) and other open storage areas
like scrap yards

d. Chemical storage, hazardous waste storage / disposal facilities etc.

e. Service buildings and allied facilities

f. Site topography including elevation, slop and drainage

g. Seismic data and probability of tsunami in coastal areas

h. Highest flood level in the area, water table, natural streams/ canals

i. Approach roads for functional areas

j. Aviation considerations like height restrictions and distance from flight path

k. Environmental considerations

l. Statutory requirements, airport operator’s requirements, local bye-laws etc.

6.3 General consideration for the layout of the facility

While locating the various facilities the following should be considered:

a) Tank farm, loading / unloading gantry, utilities, OWS (wherever required) and approach roads
should be suitably constructed to prevent flooding.
b) SCADA/server room room should be located in a non-hazardous area, upwind (Majority of the
year) of hydrocarbon storage and handling facilities and at a distance from potential leak sources.
It shall not be located on a lower level than surrounding plants and tank farms.
c) The control room for Pipeline receipt (if applicable) can be co-located with the SCADA/server
room for the AFS.
d) Utility block(s) shall be located outside the hazardous area.
e) Overhead power transmission lines shall not pass over the AFS including the tank truck parking
areas. Horizontal clearance shall be in line with the Indian Electricity Rules.
f) High Tension (HT) line and HT sub-station(s) shall be terminated /located outside the hazardous
area.
g) Tank truck/refuellers movement inside the AFS shall be kept to minimum and for this purpose the
truck/refuellers loading / unloading facilities should be located at a safe distance near the gate
meant for its movement and should be oriented to provide one-way traffic pattern for entrance and
exit. Tank truck/refuellers in the gantry shall be in drive out position for easy escape in case of
emergency.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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h) For AFSs with storage capacity more than 1000 KL above ground tanks, drain shall be provided
around the Tank farm, TT/Refuellers loading/unloading area to collect product due to accidental
spill over / leakage and shall be routed to OWS/pits. The drains shall always be maintained clean.
i) Roads should be provided in a symmetric manner to the extent possible to serve all areas
requiring access for the operation, maintenance and firefighting.
j) Smoking booths shall not be provided inside an Aviation Fuel Station.

k) Firewater storage & firewater pump house, wherever applicable, should be located upwind of
hydrocarbon storage area with straight approach from outside area to enable easy receipt of
mutual aid and make up water.

The provision should be made to receive the water from other sources including mutual aid /
sharing of water into fire water storage tanks.

l) All buildings which are not related to AFS operation should be located at upwind of hydrocarbon
storage & handling facilities. These shall be located outside the hazardous area. These areas
include administration, canteen with a separate entry. Special care need to be taken for canteen
location where any spark or open flame is likely to exist.

m) Congestion inside the hazardous area because of buildings, structures, pipelines, trees etc.
should not be allowed. The location of such addition of facilities in existing AFS shall be decided
based on Risk Assessment.

Electrical equipment /fittings of type suitable for respective area classification (Zone-0,1,2) to be
ensured. Electrical fittings as well as electrical equipment in hazardous areas should be flame-
proof. Adequate number of portable fire extinguishers should be placed as per details provided in
this standard.

n) The additives shall be stored at the designated / segregated area as per respective Material
Safety Data Sheet.

o) Unlicensed area to be suitably demarcated by fencing.

6.4 Layout of storage tanks

6.4.1 Dyked Enclosures:

a) Above ground ATF storage tanks shall be located in dyked enclosures. Each dyke shall have roads
all around for aggregate tankage more than 5000 KL, for access during normal operation and
maintenance as well as for emergency handling. Aggregate capacity (combined safe capacity) of
tanks located in one dyked enclosure shall not exceed 60,000 KL for a group of fixed roof tanks.

b) Dyked enclosure shall be able to contain the complete contents of the largest tank in the dyke in
case of any emergency. A free board of minimum 200 mm above the calculated liquid level shall be
provided for fixing the height and capacity of the dyke.

c) Enclosure capacity shall be calculated after deducting the following volumes:

i. Volume of the tanks other than largest tank up to enclosure height without free board.
ii. Volume of all tank pads/supports/RCC rings as applicable.
iii. Volumes of fire break walls.
iv. Volume of pipes/supports/steps etc.

d) The height of tank enclosure dyke (including free board) shall be at least 1.0 M and shall not be
more than 2.0 M above average inside grade level.
However, construction of dyke exceeding 2 M may be considered where there is severe constraint
on space availability, subject to approval of PESO. In such case, following conditions must be
fulfilled:

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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i. Total dyke capacity shall be based on containment of largest tank capacity.

ii. Monitors on raised platforms shall be provided so that throw of the monitors are not restricted.
iii. All tanks in such a dyke shall be provided with sprinkler system for AFSs storing more than
1000 KL in above ground tanks.
iv) The dyke wall made up of earth, concrete or solid masonry shall be designed to withstand the
hydrostatic load and shall be impervious. Dyke enclosure area (inside area of the dyke) shall
be also impervious to prevent the ground water pollution. Dyke enclosure (entire area of the
dyke) shall have impervious layer of suitable material such as EPDM (ethylene propylene di-
monomer) liner / polyethylene sheet to prevent the ground water contamination in addition to
brick/stone pitching / PCC etc.
v) Suitable railing for fall protection to be provided.

e) The dyke and the enclosures will be inspected for cracks, visible damage etc. every six months
(pre and post monsoons) and after every major repair in the tanks / dykes etc. so as to keep it
impervious.

f) Piping through dyke wall, if any, shall be properly sealed to make dyke impervious.

g) The dyke area shall have proper slope outward of tank pad towards the inner periphery of the dyke
enclosure to prevent reverse flow.

h) Earth-pits shall be provided outside of Dyke area and strips buried under the earth except at
termination points from a shortest possible distance. The earthing lay out diagram shall be displayed
for reference.

i) Pump stations and piping manifold should be located outside dyke areas.

j) Horizontal above ground tanks mounted on pedestals shall meet separation distances and shall
have dyked enclosure.

k) Inter distance between dyke wall and tank shell shall be minimum half the height of the tank.

l) In case of buried tanks - Under Ground (UG/buried) & Semi-buried (SB) tanks:

i. Kerb wall of minimum 300 mm height should be provided in the UG/SB tank Farm Area to
contain accidental overflow.

ii. A minimum of 1.5M clear distance from the tank shell shall be maintained from structures /
boundary.

iii. Vents shall be located / terminated at a distance of 4 M from hazards and shall be at
minimum 4 M height from the ground level.

iv. The open end of free vent pipe shall be covered with non-corrodible metal wire gauze having
60 meshes and shall be further protected from rain by hood or by suitably bending it
downward.

v. Aviation fuels shall enter a tank through closed piping system/coupled electrically continuous
and sound hose.

vi. The manholes, dip hatch, floating suction inspection hatch and pipelines should be minimum
300mm above the grade level of the tank farm.

m) Corrosion control measures like provision of Cathodic protection for hydrant pipelines, wrapping-
coating for buried pipelines and tanks, epoxy lining of tanks & hydrant pipelines, etc. shall be
undertaken.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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6.4.2 Grouping of Tanks:

a) Tanks shall be arranged in maximum two rows so that each tank is approachable from the road
surrounding the enclosure.
b) Tanks having 50,000 KL capacity and above shall be laid in single row.

6.4.3 Fire walls inside dyke enclosure for above ground tanks;

a) In a dyked enclosure where more than one tank is located, firewalls of minimum height 600mm
shall be provided to prevent spills from one tank endangering any other tank in the same
enclosure.
b) A group of small tanks each not exceeding 9 meters in diameter and in all not exceeding 5,000
cum in capacity shall be treated as one tank for the provision of firewall.

6.4.4 General

a) The tank height shall not exceed one and half times the diameter of the tank or 20 m for above
ground vertical tanks, subject to height restrictions at the airport, whichever is less.
b) All Piping from / to any tank including connected sprinkler / foam line shall comply with the
following:

i) Shall not pass through any other dyked enclosure.

ii) Shall run directly to outside of dyke to minimise piping within the enclosures.
iii) Shall not pass through other tank areas / fire walls.

Piping design inside tank dyke area should ensure easy accessibility for any operations in the tank
farm. Elevated catwalks above the height of the dyke wall shall be provided for safe access and exit in
case of normal / emergency situations. The catwalks shall run at the same level and terminate directly
outside the dyke.

c) No part of the dyked enclosure shall be below the level of surrounding ground immediately around
the outside of dyke area.

d) The minimum distance between a tank shell and the inside toe of the dyke wall shall not be less
than half the height of the tank.

e) Properly laid out road should be provided for easy access on all four sides of each dyke,
wherever feasible.

6.4.5 Protection of facilities:

a) Properly laid out roads around various facilities should be provided within the AFS for smooth
access of fire tenders etc. in case of emergency, for AFSs storing more than 1000 KL in above
ground tanks.

b) For AFSs located outside airport/defence premises, the boundary wall should be constructed as
per the directives of the Ministry of Home Affairs or any other Government directive. In any case
the boundary wall shall be of minimum 3m height with V/Y shaped barbed wire fencing on the wall
with 600 mm diameter concertina coil on top.

c) The emergency gate shall be away from the main gate for evacuation of vehicles and personnel
in emergency and shall always be kept available and free from obstruction.

d) CCTV shall be installed in AFSs, other than defence, with aggregate storage more than 5,000
KL, covering entry/exit gate, periphery of installation and all critical operating areas like tank farm,
loading/unloading area, etc. which should be monitored continuously. The CCTV monitoring
station should be provided in SCADA/SHIFT room, security cabin and in-charge room.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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6.4.6 Separation distances:

a) Minimum separation distances between various facilities described above shall be as per Table-1,
2 & 3. The table shall be read in conjunction with the notes specified with the table.

b) The layout shall also take into account findings/recommendations of HAZOP/ Quantitative Risk
Assessment study, which shall be carried out at all the stages of facility development process. For
existing AFSs, the same has to be carried out in line with requirement of Factory’s Act is
irrespective of tankage capacity.

c) For large AFS, minimum separation distances are specified in Table- 1. The table is applicable
where total storage capacity for ATF in above ground tanks is more than 5000 KL.

d) For medium sized AFS, minimum separation distances shall be as specified in Table-2. This table
is applicable where total above ground storage capacity for ATF is equal to or less than 5000 KL
but more than 1000 KL.

e) For “other” category AFSs, minimum separation distances shall be as specified in Table-3. This
table is applicable where total above ground storage capacity ATF is equal to or less than 1000
KL or where AFSs are having only buried /semi-buried tanks irrespective of storage capacity.

f) Existing AFSs with capacity more than 1000 KL above ground tanks where inter distances
between tanks in a dyke and / or within dykes and other facilities are not conforming to the Table
1 and 2 following additional facilities shall be provided to enhance safety:

i. The fixed water spray system on all tanks, irrespective of tank diameter at locations where
required water is available from local resources. ii.Either fixed or semi fixed foam system on all
tanks or minimum 2 nos. Trolley-mounted HVLR (variable discharge type).irrespective of tank
diameter.

iii. Additional 75 kg DCP fire extinguishers shall be positioned at other facilities not meeting
safety distances.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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TABLE – 1
SEPARATION DISTANCES BETWEEN FACILITIES FOR LARGE AFSS WITH ABOVE GROUND TANKAGE > 5000 KL
11
S.No. From / To 1 2 3 4 5 6 7 8 9 10

(D+d)/4 0.5D or 20 15
1
Storage Tank- Class B or 10 min 15 30 min 30 30 30 8 30 15
2
Tank vehicle loading/unloading for 15
petroleum Class B 15 x 30 20 30 30 30 8 30 15
3 X
Fire water tanks & Pump House 30 30 x X 12 30 6 30 12 30
0.5 D or 1.5 X
4
Boundary wall around AFS 20 min 20 X x X X X X 15
3
5
Service/office buildings/workshop 30 30 12 X X 30 X 8 X 15
6
15
OWS 30 30 30 1.5 30 X 30 X 30 30
Electrical Panel Room (PMCC/DG X
7
room)/Electrical Sub station 30 30 6 X X 30 x 8 X 15
15
8
FLP Electric Motors 8 8 30 X 8 X 8 x 8 8
X
9
SCADA/Server Room 30 30 12 X X 30 X 8 X 30
DP shed (Class A in packed 15
10
condition) 15 15 30 15 15 30 15 8 30 X
11
Non-FLP Motors 15 15 X X 3 15 X 15 X 15 X

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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General Notes to Table-1:

a) All distances are in meters and the table specified the minimum requirement.

b) “D” indicates the diameter of the larger tank.

c) All distances shall be measured between the nearest points on the perimeter of each facility except (i) In case of tank vehicle loading / unloading area
where the distance shall be from the centre of nearest bay.

d) Service building shall have minimal manning and normally no hot work would be done there.

e) “ X ” means any distance suitable for constructional or operational convenience

f) Safety distances between tanks are not applicable (other than boundary wall) for double walled above ground storage tanks. No dykes are required
for such tanks.

g) Pig launcher/receiver at liquid hydrocarbon handling pipeline installations should be located at least 5 m from boundary.

Specific notes to Table-1:

1. OWS shall be minimum 1.5 m from boundary wall. However, OWS in this case shall have permanent covers with venting arrangement located at
minimum 4 m from boundary wall and other hazard.

2. Refuellers parking space should be demarcated and a minimum distance of 4m distance to be maintained from the centre line of the nearest
refuellers to the boundary wall.

3. Fixed type Proving Measure should be at a minimum distance of 4 m from hazard.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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TABLE - 2

SEPARATION DISTANCES BETWEEN TANK / OFFSITE FACILITIES for AFSs with Above Ground Tankage >1000 &<=5000KL

11
S.No. From / To 1 2 3 4 5 6 7 8 9 10

1
D or 4.5 D or 4.5
Storage - Class B 0.5D 4.5 min min 4.5 4.5 3 9 30 4.5 D min
2
Tank vehicle decantation /
Topping-up 4.5 X 4.5 4.5 4.5 4.5 1.5 9 30 9 9
D or 4.5
3
Boundary wall around AFS min 4.5 X X X X X 9 X 1.5 X
D or 4.5
4
Service/office buildings/workshop min 4.5 X X X X X 9 12 9 x
5
Non-FLP motors 4.5 4.5 X X X X 3 9 x 9 x
6
Electrical Panel Room (PMCC/DG
room)/Electrical sub statin 4.5 4.5 X X X X 3 9 X 9 x
7 FLP Electric Motors 3 1.5 X X 3 3 X 3 30 X 3

8 DP shed (Class A in packed

condition) 9 9 9 9 9 9 9 x 30 9 9

9 30
Fire water tanks & Pump House 30 30 X 12 X X 30 30 x 12
10
OWS 4.5 9 1.5 9 9 9 X 9 30 x 9
11
SCADA/Server Room D min 9 X X X x 3 9 12 9 x

Notes:
Safety distances between tanks are not applicable (other than boundary) for double walled above ground storage tanks. No dykes are required for such tanks.
Notes given under Table 1 are applicable for Table 2.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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TABLE - 3

SEPARATION DISTANCES BETWEEN TANK for AFS with Above Ground tankage <=1000 KL or Buried/Semi Buried tanks irrespective of capacity.
9
S.No. From / To 1 2 3 4 5 6 7 8

D or 4.5
1 0.5D ( note 4.5min D or 4.5
Storage - Class B b) 4.5 ( note b) min 4.5 3 9 4.5
2 4.5
Tank vehicle decantation / Topping-up 4.5 X 4.5 4.5 4.5 1.5 9 4.5
3 X
Boundary around AFS D or 4.5 min 4.5 X X X X 9 X
4 X
Service/office buildings/workshop D or 4.5 min 4.5 X X X X 9 X
5 X
Electrical Panel Room (PMCC/DG room) 4.5 4.5 X X X 3 9 X
6
3
FLP Electric Motors 3 1.5 X X 3 X 9 X
9
7 DP shed (Class A in packed condition) 9 9 9 9 9 9 X 9
X
8 Non-FLP motors 4.5 4.5 X x x X 9 X
X
9 SCADA/Server Room 4.5 4.5 X X X 3 9 X

General notes to Table –3:

a) All distances are in meter and the table specifies the minimum requirement.
b) Distance norms between buried / semi buried tanks will not be applicable. The distance between buried/semi buried tanks & boundary shall be minimum 1.5 m.
c) “x” indicates suitable distance as per good engineering practices to meet construction, operational and maintenance requirements
d) “D” indicates the diameter of the larger tank.
e) Distances given for the tanks are shell to shell in the same dyke.
f) Where alternate distances are specified (like 0.5 D / 6.0), the minimum thereof shall be used.
g) All distances shall be measured between the nearest points on the perimeter of each facility except in case of tank vehicle loading /unloading area where the distance
shall be from the centre of each bay.
h) Pig launcher/receiver should be located at least 5 m from boundary.
i) Safety distances between tanks & other facilities (other than boundary are not applicable for double walled above ground storage tanks. No dykes are required for
such tanks.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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For Aviation Fuel Stations:

1. For underground & semi buried tanks the separation distance between Tank Vents and hazard should be minimum 4 m. The vertical separation should be minimum 4 m
from the grade level.
2. Separation distance of 1.5 m to be maintained from underground and semi buried tanks to nearby structures and boundary wall. For above ground tanks Table 3 to be
followed.
3. Refuellers parking space should be demarcated and a minimum distance of 4m distance to be maintained from the centre line of the nearest refuellers to the boundary wall.
4. Fixed type Proving Measure should be at a minimum distance of 4 m from hazard.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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7. DESIGN CONSIDERATIONS

7.1 Types of storage tanks

i) Horizontal tanks: Above ground, Underground and semi-buried Tanks

All horizontal tanks –above ground, underground and semi buried, shall be as per BIS 10987 or any
equivalent industry standard.

ii) Fixed Roof Tank

Fixed roof may be of cone type. For designing atmospheric pressure tanks, API STD 650 or IS 803 or
any other equivalent shall be followed.
7.2 Selection of type of storage tanks

Selection of type of tank generally depends on ambient conditions, site requirement and the volume of
product to be handled.

7.3 Special Considerations

Tank bottoms should be cone down with a continuous slope towards centre sump for vertical tanks
as per industry standard and horizontal tank should be installed with a continuous slope of 1:60
minimum.

7.4 Tank appurtenances

i. Ladders and Handrails:

Individual above ground vertical and horizontal tanks shall be provided with access to the roof or
tank top. A platform with railing should be provided from the top of the stairway to gauge well,
vents and floating suction check point.
ii. Stairs:

Stairs should be made of grating. All staircases shall have resting/landing platform for every 5m
height.

iii. Manholes:

Minimum two number of roof manholes and 2nos. of shell manholes to be provided in all vertical
tanks. For horizontal tanks minimum two numbers of manholes shall be provided.

iv. Walkway on the Roof:

Walkway with hand rail on the roof of the tank should be provided to facilitate inspection/checking
of vents etc. so that movement of personnel on roof is safer. Anti-slippery path on the roof should
be provided for this purpose.

v. Floating suction: All Aviation tanks shall be provided with floating suction of size depending on
the tank capacity and discharge flow rate, with an inspection hatch at the top of the tank.

vi Sampling sump: to be provided in all types of Aviation tanks.

vii sampling draw off line and water draw off line: For vertical tanks minimum one no. sampling
draw off line and / or one water draw off line should be provided.

Viii Vents: Adequately sized free vents to be provided for ATF tanks as per API 2000. Vents should
be fitted with a protective screen of 60 mesh size.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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7.5 Tank farms/manifolds

7.5.1 Tank Farm Drains for AFS with storage capacity > 1000 KL

The dyke drain shall be provided along the inside periphery of the dyke enclosure wall. In case
circular drain around tank pad is provided, the same needs to be connected to the peripheral drain.

The outlet from dyke shall have the provision to divert to the OWS or to main storm water drain.

AFS with total tankage of more than 5000 KL in above ground tanks, the dyke drain valves shall be
provided with position indication and alarm system.

7.5.2 Tank Manifold

i) The number of inlet/outlet connections to the tank shell should be kept minimum.

Tank body valve of above ground tanks shall be manually operated valve.

The second valve on above ground tanks should be motor operated valve (MOV) on inlet and
outlet lines for locations having hydrant refuelling system. For other AFSs, in place of MOV,
manual operated valve may be provided. This second valve can be located outside the dyke area.

All AFSs with above ground storage capacity more than 5000 KL shall have over-fill protection
system
ii) Hammer blind valves of any type shall not be used in AFSs.
iii) MOV should have open & close remote operation from SCADA/shift room and at field outside of
dyke.
In addition, open, close & stop feature should be available for local operations, close to the valve.
iv) Tank manifold(s), if provided, should be located outside the dyke area. The floor underneath the
manifold shall be paved and have Kerb walls and connected to oil water drainage system leading
to OWS.
v) Thermal safety valve (TSV) / Expansion line should be provided in above ground tanks for
blocked portion of pipe line(s) to take care of the thermal expansion of product due to rise of
temperature.

TSV outlet line or expansion line should be connected back to above ground tank / tank
inlet/outlet line before manually operated body valve with suitably positioned isolation
valve(s).One isolation valve shall be installed close to the tank body/inlet/outlet line to the
maximum extent possible.

In case the expansion line is connected at tank top, the line shall be extended inside up to the
Tank bottom to avoid free fall thru vapour space. However, at existing locations where ever the
above provision does not exist in above ground tanks, the same shall be provided on all tanks
during scheduled tank maintenance / cleaning.

vi) Any electrical fittings and fixtures inside the dyke shall be as per the hazardous area
classification. However such fittings and fixtures except for actuators of MOVs should be above
the dyke height.

7.5.3 Tank Settlement

Settlement of tanks takes place over a period of time and a depression is formed on tank pad along
the circumference. The same should be effectively made up with proper slope to avoid rain water
accumulation and subsequent corrosion of the bottom plate. Where large settlement is anticipated,
supporting arrangement for the connected piping shall be suitably designed to take care of the
settlement.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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7.6 Drain/sampling point

7.6.2 Drain/sampling point in Above Ground tanks

Arrangement should be provided in all above ground tanks for product sampling and water draw off
from tanks. These are also useful for draining water after a hydro test or initial flushing during a start-
up operation. Number and details of the drains shall be as per the applicable tank design standard.

Each drain line shall have minimum two isolation valves and pipe extended beyond tank pad up-to
drain point. One of these valves shall be of quick closing type. Ends of each drain point should have
provision of blind flange/capping arrangement.

7.6.3 Drain/sampling point in Buried / Semi Buried tanks

Arrangement should be provided in all buried and semi buried tanks for product sampling and water
from tank sump.

7.7 Vents

Open Vents
For sizing the vents API STD 2000 is to be referred. However, following are the basic guidelines need
to be considered:

a. Maximum and minimum ambient temperatures.

b. Vapour pressure of the product at operating/design temperature.
c. Maximum pumping in and out rates. In the event of change in any operating parameters
involving change in pumping rates complete end to end system check shall be done in line
with Management of Change. for details refer annexure(4) and(5).

7.8 Dip Hatch/Sampling

a) Dip hatch or gauge hatch is used for gauging the height of the liquid in an above ground tank
as well as to take out samples for testing. In underground and semi buried tanks, separate
sampling hatch is provided in addition to dip hatch for gauging purpose.

b) Gauge well pipe (with slots) should be provided for all types of tanks.

c) The gauge well should be properly supported by means of angles/strips with bottom plate of
the tank. The above arrangement also makes the tank safer with respect to dissipation of
static charge accumulation.

7.9 Instrumentation

i) Safety Integrity Level (SIL)

The SIL classification study should be carried out for AFS having hydrant refuelling system and
pipeline receipt with storage capacity more than 1000 KL above ground, to determine the required SIL
level. SIL of the safety instrumented function for the tank including overfill protection shall be meeting
the requirement of Part 1 of EN 61511.All instrumentation equipment shall have required SIL
certification based on the above study.

ii) Level controls on Tanks

Position of level alarms:

High Level (H): Between normal fill level and safe fill level

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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High High Level (HH): At safe fill level (PESO approved stored volume)

“H” and “HH” level switches shall have provision of audio & visual alarms on auto-actuation in the
control room.

The above alarms shall be provided as given below :

AFS with total storage NIL

less than or equal to requirement.
1000 KL above ground.
AFS with total storage Hi , Hi-Hi and
5000 KL and more shut down
( above ground tanks) system
AFSs with above ground Hi level alarm.
storage capacity more
than 1000 KL & less than
5000 KL.

The above shall be applicable to all locations.

There shall be exchange of signals between the receiving and dispatch location in case of receipt of
product through cross country pipe lines. Provision shall be made for monitoring of level of the
receiving tank along with pressure in the pipe line and MOV status and to ensure safe shut down of
the system in case of any abnormal situation.

Care need to be taken for tanks receiving product from cross country pipeline at high flow rates for
surge pressures due to sudden closures of valves and accordingly where ever required, suitably
designed Surge relief system /pump tripping to be provided.

7.10 Piping/valves/flanges

Piping: should be designed for handling of Hydrocarbon liquid as per “ASME B 31.3: Process Piping”
or ASME B 31.4 (for cross country pipelines only entering the AFS) or API 5L or equivalent as
applicable.

Pipe joints should be welded as far as practicable with full penetration weld. Number of flanged or
threaded joints should be kept to a minimum.

In case sampling point is provided on receipt line for operational requirement, the same should be
provided outside of dyke in the manifold.

Sectionalizing of the pipe lines with isolation valves and arrangements for injection /draining of water
shall be provided for facilitating hydro-testing of the pipe lines.

Buried piping shall be protected against physical damage and corrosion with suitable protective
coating.

The product hydrant pipelines should be provided with low point and high point drains to facilitate
emptying /sampling/hydro-testing etc. Ends of each drain point should have provision of blind
flange/capping arrangement.

Valves for handling aviation product:

Steel valves for handling aviation products should conform to relevant API or equivalent standards. .
Cast iron valves shall not be used for handling aviation products.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Fittings for handling aviation product:

Steel flanges and flanged fittings shall conform to relevant ASME / ASTM/ANSI or equivalent.
Slip on or weld neck flanges should be used.

Screwed flanges for sizes 50 mm or smaller may be used.

Steel flanges should conform to the applicable provisions of ASME B 16.5 or equivalent.

Steel screwed fittings and couplings shall conform to ASME B 16.11 or equivalent.

Steel unions shall have ground metal to metal seats. Gasket type unions shall not be used.

Plugs shall be of steel. Cast iron or brass plugs shall not be used.

All flanges shall be connected for bonding for electrical continuity.

7.11 Bulk Loading /unloading operations

i) Loading / unloading Pumps

a) Pumps conforming to relevant API standards may be used.

b) Product pumps may be provided with suitable sized strainers on suction and NRVs on
discharge lines. All drain points of strainers shall be provided with isolation valves and ends
having provision for blind flange / screw capped

c) Pumps shall be located in an exclusive paved area with drainage facilities routed to OWS for
AFSs with more than 1000 KL above ground tanks.

d) Pump house shall be positioned at an elevated platform and shall be well ventilated on all four
sides.

e) Pump-motors are to be provided with suitable IP protection

f) To avoid wide variation in pressure, leading to a ‘kick’ or ‘hammering’ in header and hoses, it
is necessary to choose pumps with flat characteristic curves.

g) Unloading/loading pumps shall also be provided with additional flame proof switch located at
the strategic location in the gantry/loading-unloading bays to switch off the pump in case of
emergency such as over flow, fire or any other abnormal situation.

h) In addition to above, locations having automation shall be provided ESD (Emergency

Shutdown) feature through automation system.

i) Suction and discharge lines at AFSs with above ground tanks shall be provided with thermal
safety relief device to relieve pressure due to ambient temperature rise. Thermal Safety relief
device may vent into a tank. When connected to tank, it (TSV) shall be provided with isolation
valves, which shall be locked open. One isolation valve shall be installed close to the tank
body to the maximum extent possible.

ii) Tank truck and Refuellers Loading Bays.

a) Tank Truck and refuellers should be bottom loaded.
b) Loading unloading points shall have quick shut-off valves e.g. Cast steel Plug or Ball Valves.

c) Automated locations may be provide suitable overfill protection system to prevent any
overflow and hazards arising out of that.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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d) Loading hoses for Tank Trucks and refuellers shall be as per relevant API/EI/EN/BIS
specifications.
e) Flameproof lighting or portable flame proof torches shall be provided for night time checking
of bottom leaks of trucks and also for proper sealing and inspection wherever
loading/unloading during night is required to be done.
f) Operating personnel of large size AFSs (storage more than 5000 KL) shall be provided with
intrinsically safe walkie-talkie sets.
g) AFSs with Tank Truck unloading/loading gantries and refuellers loading gantries shall be
provided with safety harness to protect the operating crew against fall from height.

h) Swing type loading ladders with counter weight & hand railing, wherever provided, shall be
light in construction. Neoprene packing shall be provided at the bottom rest to avoid spark
generation due to impact.

i) Proper handrail arrangement should be provided on platforms and stairs for safe movement
of personnel.

j) Provision shall be made for quick isolation of main product headers in case of emergency. For
this purpose, suitable type hand operated valves or remote operated valves should be
considered as per the site conditions and overall automation system in the AFS.

k) Loading and unloading bay area shall be paved for smooth draining and collection of spillages
into drains.

l) Open drains shall be covered with gratings so as not to endanger movement of personnel.

m) All tank trucks/refuellers, if not exempted by PESO, entering licenced area shall be provided
with PESO approved spark/flame arrestor at the exhaust.

n) Oil and water collected from loading/unloading areas shall be routed to Oil water separator
system for AFSs with storage capacity more than 1000 KL above ground. A slop tank should
be earmarked for storing separated oil.

o) The loading and unloading bays shall be designed such that movement of vehicle is smooth
without criss-crossing.

7.12 HANDLING OF SLOP

Collection and Drainage for AFSs with above ground storage capacity more than 1000 KL.

A network of drainage system shall be provided to collect oil drains from various equipment,
loading/unloading areas, pump houses etc. They should also collect surface drains from places
where oil spillages are likely to occur. The drainage shall lead to OWS.

OWS

The receiving sump of the OWS shall have suitable arrangement for skimming off upper layer of
accumulated oil.

7.13 ELECTRICAL EQUIPMENT

Electrical equipment including the lighting system shall conform to hazardous area classification. The
hazardous area shall be classified as per IS: 5572 and OISD-STD-113.The electrical fittings /
equipment in the respective classified area/ zone shall be of a type suitable for the particular
area/zone as per classification in line with IS: 5571.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Electrical equipment shall be selected, sized and installed so as to ensure adequacy of performance,
safety and reliability. The equipment in general shall conform to relevant Indian Standards and shall
be suitable for installation and satisfactory operation in the service conditions envisaged.

Protection: The protection system shall be designed to ensure Protection of Personnel and plant
equipment against damage which can occur due to internal or external short circuits, overloading,
abnormal operating conditions, switching, lightning surges, etc. Accordingly, relays and protective
devices shall be suitably selected and installed. All the protective relays for the Generator,
Transformer, Motors and Switchgears shall be tested at least once in a year and test records
maintained.

Cables
In order to avoid spread of fire due to cables, the outer PVC sheath of all cables including XLPE
insulated cables used inside the dyke shall be flame retardant type conforming to category AF as per
IS: 10810. The cable shall have a low smoke property.

All power and control cables shall have extruded inner and outer sheaths. Cables should be
Aluminium /Copper Conductor PVC insulated, PVC sheathed, armoured type.

Instrument and signal communication cables shall not be laid in the same trench/tray along with
electrical cables. The overall cable layouts shall be designed for minimum interference between signal
and power cables.

Cable route markers shall be installed at every 30 metres intervals all along the cable routes and also
at cable joints and locations where the direction of cable trench changes.

A. MEASUREMENT OF EARTH RESISTANCE

The testing of the earth pits shall be done six monthly one in dry and once in wet weather and records
maintained. An earth resistance tester to be used for this purpose.

Removable link shall be provided to allow measurement of an earth electrode-resistance.

Allowable earth-Resistance Values

The resistance value of an earthing system to general mass of the earth should not exceed:
-- 4 Ohms for electrical systems and metallic structures
-- 7 Ohms for storage tanks
-- 1 Ohm for main earth grid, and bonding connections between joints in pipelines and associated facilities.
-- 2 Ohms for each electrode to the general mass of the earth.

B. AFS EARTHING

AFS earthing design shall be carried out in accordance with the requirements of Central Electricity
Authority (CEA) safety Regulation 2010 or equivalent system recognised by statutory authorities
under the petroleum act / electricity act All earth connections should be visible for inspection to the
extent possible. The earthing system shall have an earthing network with required number of earth
electrodes connected to it.

Earthing system shall be designed for the following:

1. System neutral earthing.

2. Protective Equipment Earthing for personnel safety.
3. Protection against Static discharges.
4. Lightening Protection
5. Earthing for Data Processing system, etc.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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Electrically independent earth electrodes:

Earth electrodes shall be located at such a distance from each other so that the maximum current
likely to flow through one of them does not significantly affect the potential of the other.

The Lightning Arrestor (LA) to be provided for Di Pole/ Four Pole structures and shall be connected
to two distinct earth pits. The strips shall run on insulators / isolators so as not to come in contact with
the Pole structure. Connections shall be made to the pit directly and then pits will be connected to
each other to form a grid. The Grid of LA shall be distinct and shall not be connected to any other
earth Grid.

The Di Pole/ Four Pole structure shall be earthed with two distinct earth connections. The Gang
Operated Switch shall also be earthed.

Fencing of Di /Four Pole, Transformer yard shall be earthed and also electrical continuity between
various structures the fencing shall be ensured.

The Neutral of the Transformer shall be earthed with two distinct earth pits separately. Connections
will be made to the pit directly and then pits will be connected to each other to form a grid. This Grid
shall be distinct and shall not be connected to any other earth Grid.

The Neutral of the Diesel Generator shall be connected to two distinct earth pits separately.
Connections shall be made to the pit directly and then pits will be connected to each other to form a
grid. This Grid shall be distinct and shall not be connected to any other earth Grid.

The transformer body shall be earthed at two points separately leading to earthing system.

All Metallic non-current carrying parts of all electrical apparatus shall be earthed to ensure that the
exposed metallic parts do not become dangerous by attaining high voltages in case of faults.

All the electrical equipment operating above 250 volts shall have two separate connections to the
earth. (Sub Station Panels, Motors, FLP JBs etc.).

All Steel structures, loading platform / gantries etc shall have two separate and distinct
connections. Connections will be made to the pit directly and then pits will be connected to each other
to form a grid.

Storage Tanks shall have minimum two separate and distinct connections. Each connection will be
made to the respective earth pit directly. There after these earth pits should be inter-connected to
form a dedicated grid for Tank Farm. All earth pits shall be located outside dyke area. The number of
earth pits / connections to be increased for large tanks so that the distance between the connections
does not exceed 30 meter on the tank perimeter.

For example:
For tanks up to 60 meter perimeter 2 Nos earth pits shall be provided for above 60 meter perimeter
and up to 90 meter 3 earth connections shall be provided and so on.

C. BONDING:
Flanges: All flanged connections shall be effectively bonded by strips of suitable material.
Tank Truck/Refuellers Loading and Unloading bays: For the bays minimum 6 mm Sq. braided
copper wire with one end firmly bolted to the Loading Unloading Arm / hoses and the other end
provided with G.I / Copper / Non corrodible metal crocodile clips are to be used, the crocodile clips
being attached to the tank-truck/refuellers under loading or discharging. (For External Bonding of
Loading unloading arms/hose with the Tank Truck).

SAMPLING /GAUGING: For sampling devices to be inserted into product tanks, use SS chain.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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D. STATIC EARTHING:

Static Earthing shall be provided at Tank Lorry / Refuellers loading/ Decantation Gantries, to
prevent building up of Static Charges. The Static Earthing shall be segregated from electrical earthing
to prevent it from getting energized to the same voltage level as it would exist on electrical fittings in
case of fault. This earthing shall be independent of earthing system for automation.

E. LIGHTNING PROTECTIVE SYSTEM:

Lighting protection shall be provided for the equipment, structures and buildings which are higher than
20 meters or as per the risk index analysis worked out as per IS 2309.

Self-conducting structures do not require lightning protection with aerial rod and down conductors.
They shall be connected to the earthing system at two points of the base.

If lightening arrester is provided an independent earthing network shall be provided for lighting
protection.

F. EARTHING FOR DATA PROCESSING SYSTEM:

Low noise Earthing are required for critical data processing equipment. These are to be independent
of any other Earthing of the Building.

Wherever isolation transformers are used, the output neutral of the transformer shall be independently
earthed so as to ensure that the Earth-Neutral Voltage is less than 1 volt.

G. Minimum Permissible Sizes of the Earthing Conductors:

Size of the conductor shall be selected based on the fault current that is required to be dissipated
during emergencies.

Equipment Size of the conductor

Main Earthing Grid 50mmx6 mm GI strip
Lightening Arrester of the 2/4 Pole 40mmx6 mm GI strip
Structure
2/4 Pole structure / Sub-Station 40mmx6 mm GI strip
equipment / VCB etc.
Fence of the 2/4 pole structure / 25mmx3 mm GI strip
transformer yard
Power Transformer Neutral 50mmx6 mm GI strip
Power Transformer Body 40mmx6 mm GI strip
Fire Water Pump House 25mmx6 mm GI strip
Building / Structure Columns 40mm X 5mm GI Strip
Storage Tanks 40mm X 5mm GI Strip
Push Button Stations No. 8 SWG Solid GI Wire
Street Light Poles 10 mm (3/8") GI Wire Rope
Small Equipment & No. 8 SWG Solid GI Wire
Instruments
Bonding of Pipes 25 mm square copper strip / braided flexible cable.
Motors up to 3.7 Kw No. 8 SWG Solid GI Wire
Motors above 3.7 Kw up to 30Kw 10 mm (3/8") GI Wire Rope
Static Earth at Tanker / Wagon 40mmx6 mm GI strip.
loading/ Unloading gantry
Flexible cable for Static Earth 10 Sq. mm Copper flexible cables with lugs at one end and
crocodile clip at other end.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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H. No of earth pits:

This is minimum requirement and additional earth pits shall be made such as to maintain Grid Values
below 1 Ohm
Equipment Nos
Earthing for LA 2 Nos independent
For Di / Four Pole Structure, GO, Fence 2 Nos (All metal bodies connected)
Neutral of the transformer 2 Nos independent
Neutral of the D G Set 2 Nos independent for each DG Set
Body of DG Set / control panel for DG Set 2 Nos
Sub-station –PMCC Room 4 Nos
Fire Pump House 2 Nos
Air Comp House 2 Nos
All structures Shed of Pump House / Fire 2 Nos for each structures
Engine / Loading unloading Gantry / Air
Compressor / Eng. Store etc.
Static Earth for Loading unloading Gantry 1 Nos independent for each bay.
(Tank Truck)
All 3 Phase Motors / FLP lights in each shed 2 Nos
High Mast Tower (HMT) 2 Nos for each HMT
Admin Blocks 2 Nos
Data Processing One for Metallic body parts of equipment and one
for neutral of isolation-transformer
Inspection Platform / Watch Tower / Weigh 1 Nos each
Bridge
Water Storage Tanks (Fire Water Tank) 2 per tank
Product Storage Tank Minimum 2 nos and further as defined in Clause B
above.

I. General
a) Fail safe Interlock / change over switch shall be provided between the Grid Power and the DG
power to ensure that the equipment gets supply from one source only.
b) Insulation mats as per IS-15652 standard shall be provided in the Sub Station, control panels
etc.
c) Relays/Cables shall be tested once in a year and records maintained.
d) Transformer oil shall be tested once in a year and records maintained.
J. Emergency Feeder, for AFSs with more than 1000 KL above ground storage:

Emergency Feeder shall host the following equipment:

Fire water jockey Pump, Critical lighting, Fire Siren, Bore well, Gate Barrier, safety instrumentation
and interlocks, CCTV, , UPS of automation, supply to essential firefighting equipment.

7.14 AFS lighting

Sufficient lighting shall be provided so as to enable operators to move safely within the accessible
areas of AFS and to perform routine operations. In the event of normal power failure, emergency
lighting should be operational in critical areas.

Normal lighting system shall be on 240V AC supply, whereas critical emergency lighting will be DC
based in critical areas like Sub-Station, D G Room, SCADA/Shift Room, Security cabin.

Under normal operation, both emergency and normal lighting shall be fed by normal power source.
On failure of normal supply, critical emergency lighting, wherever available may be transferred to
emergency source, until the start of D.G. set.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Critical Emergency lighting (D.C. supply based) shall be normally kept ‘ON’. During power failure,
battery bank shall be used to provide power.

Lighting shall be provided for the various facilities in the AFS. The illumination levels in different areas
shall be as per good engineering practice.

The Illumination in the operational areas including inside the dyke and manifold shall be such that
adequate visibility is there at all times for emergency and normal operations.

Lighting requirements provided during the failure of power supply is intended broadly to,

a) Facilitate carrying out of specified operations, for safe shutdown.

b) Gain access and permit ready identification of fire-fighting facilities such as fire water pumps,
fire alarm stations etc.

c) To gain access to escape route for safe evacuation of operating personnel.

Depending on the nature of job activities carried out, the minimum illumination levels for various areas
shall be as follows in line with OISD-RP-149:

Area Lux level

Main roads (Gate entry /exit , roads around TT gantry 20
Secondary roads (along storage tanks &Periphery etc.) 10
Tank farm area 20
Pump / Compressor / Dosing Sheds / Fire Pump House 100
Main Operation Area & Access Stairs (TT/Refuellers/dispenser 60
parking area and TW gantry, Tank manifold)
Maintenance shed 100
OWS Area 60
Sub Station /PMCC room 150
Transformer yard / HT Di pole area 100
Battery room , Charger/UPS rooms 150
SCADA Room bldg./laboratory 400
DP shed (for storing Class A product in barrels) 100
Admin Building 300
Security Cabin / Watch Booth 100
Stairs 50
Corridors 70

i) The lighting fixtures on various circuits shall be suitably designed so that failures of any one circuit
do not result in complete darkness.
ii) Switches controlling the lighting fixtures and exhaust fan shall be installed outside the battery
room.
iii) Switches of lighting panels installed in hazardous area, shall have a pole to break the neutral, in
addition to the poles for phases.

8.0 Safe Operating Practices in Storage and handling of bulk aviation fuels

8.1 GENERAL

This section deals with the safe operating practices and provisions applying to loading, unloading and
storage of bulk aviation Fuels at AFSs. There should be strict compliance w.r.t selection, deployment
of proper skilled manpower for effective operation and maintenance.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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8.2 SAFE OPERATING PRACTICES.

i) AFS SCADA room where ever provided shall be manned on continuous basis during operations
and in emergency.
ii) Site Specific, Standard Operating Procedures (SOPs) shall be developed. Such procedures shall
be periodically reviewed, updated and records maintained especially whenever any changes /
modifications to the facilities are made as per Management of Change procedure (MOC).

iii) The critical operating steps based on “SOPs” shall be displayed on the board near the location
where applicable.

iv) VHF handsets provided to operating personnel shall be of intrinsically safe type.

v) All operations shall be carried out under supervision of a responsible officer. Only in serious
exigencies, permission can be granted by authorized personnel subject to obtaining a reliever
forthwith. The person leaving site shall only be allowed on a valid authorization issued by the
immediate officer and records maintained.

vi) The pipe line transfer should preferably be commenced during day light. Due to urgency if
operation requires to be carried out/extended in night time, the same to be carried out under
supervision of trained & experienced staff.

vii) Manning level in the shift should be adequate to ensure coverage for normal and emergency
operations.

viii) For locations with above ground storage tanks having aggregate capacity more than 5000 KL,
the tank farm management system should be integrated with SAP/ERP. Provision of recording of
TFMS inventory levels shall be made on SAP / ERP.

ix) For locations with above ground storage tanks having aggregate capacity more than 5000 KL,
suitable interlocks shall be provided for tripping / alarm / MOV operation based on the events high
level, high high level etc.

x) The contents of the dyke drain generated from draining of tanks, any other spillage or effluent
containing oil shall be diverted to Oil Water separator (OWS) for safe disposal.

xi) Personnel protective equipment such as safety shoe, hand gloves, apron, safety goggles, safety
belt, helmet, ear muff, bump caps, self-contained breathing apparatus (SCBA), resuscitator etc. as
applicable shall be worn while carrying out operations in normal and emergency situations.
Personnel protective equipment (PPE) are equipment designed to offer protection against potential
hazards, fire, toxicity, accidental fall etc. during normal and emergency operations.

8.3 BULK HANDLING FOR MOVEMENT BY ROAD

i) Transportation of petroleum products by road is regulated by PESO through The Petroleum Rules
2002 its latest version) and the Motor Vehicle Act 1988.
ii) Containers and tank trucks shall be fabricated in accordance with the Petroleum Rules 2002 and
OISD-RP-167 POL Tank lorry design & Safety.

iii) For movement of refuellers, sampling/pit cleaning vehicles and hydrant dispensers, inside airport
premises, the relevant Motor vehicle Rules, local airport operator’s requirement and Civil Aviation
Requirements to be followed.

8.4 SAFETY PRECAUTIONS DURING TT/REFUELLERS LOADING / UNLOADING

Following precaution shall be taken due to associated hazards during transfer of Petroleum products
to or from a tank truck.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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i) Open source of ignition shall not be allowed in the area where product transfer operations are
carried out.

ii) Vapour space of not less than 5% of its capacity shall be kept in each container and 3% in each
tank truck and refuellers in respect of Class A&B petroleum products.

iii) Fire extinguishers shall be placed near the tank trucks during operations in a designated marked
place.

iv) The master switch shall be put off immediately after parking the truck in position. No electrical
switch on the vehicle shall be turned "on" or "off" during the transfer operation.

v) The first operation after positioning the truck/refuellers shall be to provide proper earthing/bonding.
Earthing/bonding shall be disconnected just before the release of the truck.

vi) All Refuelling Hoses shall conform to EI-1529/ISO 1825 standard and shall be handled with care
and hydrostatically tested once in 6 months.

vii) No repairs shall be made on the truck/refuellers while it is in the loading/unloading area.

viii) Personnel shall wear applicable Personal Protective equipment.

ix) Filling/transfer operations should be suspended immediately in the event of -

a) Uncontrolled leakage occurring
b) A fire occurring in the vicinity
c) Lightning and thunderstorm

8.5 PROCEDURES FOR OPERATION

A. LOADING/TOPPING UP OPERATIONS:

I. Check for following in a tank truck/Refuellers as per statutory regulations before accepting it for
filling:
a) Provision of PV vent, emergency vent valve (for refuellers), master valve, spark arrestor and
other safety fittings.
b) Fire screen between cabin and tank is provided. For this purpose, cabins with metallic back
over without any opening will be considered as fire screen.
c) Each tank truck shall be provided with 2 nos. of Fire Extinguishers of ISI mark (1 no.10/9 kg
DCP and 1 no. 1 kg CO2 /equivalent approved fire extinguisher in driver’s cabin).
d) Each refuellers shall be provided with 3 nos. of Fire Extinguishers of ISI mark (2 no.10/9 kg
DCP and 1 no. 1 kg CO2 /equivalent approved fire extinguisher in driver’s cabin).
e) Spark arrestors, unless exempted by PESO, shall be welded on the exhaust.
f) No leakage in exhaust silencer pipe.
g) Valid Explosive License with PESO approved drawing and RTO certificate is available.
h) Availability of brazed copper strip for earthing / bonding connection.

II. Move vehicle to the loading/topping up bay.

III. Place the truck/refuellers on loading/topping up bay and place wheel chokes at front and rear
wheels. Keep the truck/refuellers in neutral mode with hand brakes "ON".
IV. Stop the engine and switch off all electrical equipment.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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V. All persons should leave the driver's cabin.

VI. Provide earthing connections of the vehicle at specified point to the fixed grounding system.

VII. Ensure tank vent valve is open and fire extinguisher is readily available near loading point
VIII. Start the loading/topping up operations.
IX. The quantity loaded into the truck/refuellers can be assessed by -Liquid recorded through
manual dipping/dial gauge reading.

B. UNLOADING OPERATIONS

i) Necessary steps described under clause 8.5(a) should be carried out.

ii) Test the connections for leaks

iii) Start the Unloading operations

iv) Before releasing the trucks, ensure that valves are closed/ends are capped.

v) An authorized person of the company shall supervise the unloading operation and respond
immediately in the event of an emergency.

Checklist for bulk petroleum products tank trucks at loading / unloading locations is given at
Annexure-(2)

8.6 PIPELINE TRANSFER OPERATIONS

Pipeline transfer of ATF is carried out through dedicated pipeline for receipt of ATF at the AFS from
refineries / cross country pipeline/ marketing terminal/other AFSs within the same company or
between oil companies.

Where ever pipe line transfer is envisaged between various companies, a mass flow meter/flow meter
with integrator shall be installed on receipt line. Signal shall be provided in the control rooms of both
despatching and receiving companies for monitoring.

The following safe practices to be followed:

i) Gauging procedure shall be completed and line shall be made through.

ii) Physical inspection shall be carried out up to the exchange manifold for any leakage/damage etc.
iii) Line up shall be started from the exchange pit end
iv) Seal the pressure relief lines of receipt nozzles of product tanks connected to the same common
receipt header.
v) After ensuring that there are no leaks, pumping shall be commenced
vi) Pumping shall be commenced initially at low flow rate and only after stabilizing of flow, the flow
rate may be increased.
vii) Product shall not be pumped beyond safe filling height of the tank
viii) After completion of the receipt, pumps must be stopped
ix) In case of Emergency Shutdown, care shall be taken so that back pressure is not developed in
the pipelines and pump head.
x) Sampling shall be carried out as per provisions of DGCA approved Quality Control Manual.
xi) Pipe Line transfer (PLT) from a pipeline shall not be taken simultaneously in more than one tank.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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xii) In case product is required to be taken into more than one tank, tank should be switched over
after completion of operation in first tank, close all valves to the first tank, make line through for
the second tank as per procedure.
8.7 TANKFARM OPERATIONS: SAFETY PRECAUTIONS IN TANK FARM AREA

i) Whenever operations are not in progress, 100% closure of all the operating valves must be
ensured and they shall not be left in partial open condition.

ii) All electrical fittings shall be maintained to ensure its integrity and type of protection.

iii) The tank farm must be kept clean and free from vegetation.

iv) Tanks must be periodically checked for leakages / sweating and repairs must be immediately
carried out whenever scaling / pitting are observed. Ref OISD STD 129.

v) Proper earthing and bonding shall be maintained and ensured at all times for the tank body,

vi) Dyke drain valve shall be in closed condition and shall be operated only under supervision of an
authorised person and log book maintained.

vii) Isolation Valves on expansion line(s)/TSV vent line(s) shall be always kept open except under
requirement during location specific operations to take care thermal expansion.

viii) No gauging or sampling of tanks should be undertaken during thunder or hail storms.

ix) Flow velocity at tank inlet should not exceed 1 m/s until the inlet is completely submerged.

For easy reference, permissible flow rates for initial filling are given below:

Size (in mm) of Max.Flow Rate

Inlet Pipe (KL/hr)
300 246
250 168
200 109
150 59
100 27
80 25.5

x) Safety shoes/PPEs shall be worn by the operating staff in the operational area.

xi) Tank dip pipes shall be extending to tank bottom. If dip pipes are not provided, give a relaxation time of
30 minutes before sampling/gauging.

xii) Synthetic fibre cord shall not be used for sampling, gauging etc. If the sampling, gauging, etc.,
equipment is a conductor, the cord must be conductive, e.g. a metal wire/chain. Proper bonding to be
provided in this case.

xiii) While cleaning the tanks, care should be taken to avoid generation of static electricity.
• Cleaning of tanks by gas oil spray shall not be permitted.
• Cleaning of tanks by steaming shall not be permitted for Class A & B products.
Earthing and bonding connections shall be ensured during the entire operating process.

8.8 METHANOL HANDLING AT AFS

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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i. For piston engines methanol/water mixtures (MWM) are used and these may have 1% of anti-
corrosion oil added. The injection system may be used to compensate the power lost when
operating under high temperature and/or high altitude conditions where air densities are very
low or to obtain increased take off power under normal atmospheric conditions by permitting
high boost pressure for a short period.
ii. In the case of turbine engines, water alone or Methanol/Water mixtures are used, to restore
the take-off power or thrust lost when operating under low air density conditions. Use of a
corrosion inhibitor in thrust augmentation fluids used for these engines, is not permitted.
iii. The principal grades of Methanol Water Mixtures in use is MWM (45/55/0). In this grade 45
parts of PBM (Power Boost Methanol) is mixed with 55 parts of de-ionized water and there is
no corrosion inhibitor which is denoted by ‘0’. This grade is used in the turbine engines in
Aircraft like Avro, Fokker Friendship, etc.
iv. Raw water has minerals in the form of metal salts. These minerals have to be removed from
water. This removal of minerals from water is achieved by Ion exchange process. The water
thus produced is de-ionized water. It may be either purchased from outside source; stock
transferred from another location or refinery or may be generated at the location itself.
v. Containers used for storage of De-ionized Water shall be of high density polythene (HDP) or
stainless steel and will be flushed clean before use.
vi. High density Polythene (HDP) pipes shall be used for transferring De-ionized Water from one
container to another.
vii. The HDP container shall be handled with care to avoid damage.
viii. The container shall always be kept closed and in a clean condition.
ix. DP Shed of required dimensions duly approved by PESO shall be provided for storage of
PBM. An authenticated copy of the approved drawing from PESO, showing the DP shed shall
be available at the location.
x. For transporting PBM barrels in trucks, a suitable road permit must be obtained by the
consignee from local Excise authorities and sent to the consignor. The permit shall indicate
the storage licence number of the consignee and total quantity of PBM being dispatched in
barrels.
xi. De-ionized Water used for blending of Methanol Water Mixture shall be as per the
requirements laid down in the QC Manual.
xii. Blending of Methanol Water Mixture is carried out in a blending unit kept in a ventilated area.
xiii. The blending unit has two identical containers which are provided with level indicators.
xiv. De-ionized Water and PBM shall be pumped into the blending unit through a hand pump in
the required proportion. Only polythene pipes and stainless steel pipes shall be used for
suction of PBM and De-ionized Water.
xv. Both PBM and De-ionized Water are simultaneously allowed to mix in a blender, by adjusting
the valves in the blending unit. The Methanol Water Mixture is drawn out of the unit and
loaded into the MWM refuelling unit, through a funnel provided with 100 mesh strainer.
xvi. All the sampling procedures and tests required as per Quality Control Manual shall be carried
out.
xvii. In case where blending units are not available, blending may be carried out in the refuelling
unit itself. Refuelling of MWM is through a refuelling unit kept specifically for that purpose and
is refuelling in special tanks in the aircrafts. All precautions taken in normal refuelling is done
for MWM refuelling also.
8.9 REFUELLING OPERATIONS:

8.9.1 Aviation refuelling Equipment:

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Aircraft Refuellers or Bowser – It will be designed and constructed as per Petroleum Rules,
Motor Vehicle Rules and other statutory requirements. Each refuellers shall comply with the
requirements of PESO licence, local RTO, local Weights & Measure etc.

Salient features in a Refuellers / Hydrant dispenser:

a. Refuellers tank shall be either mild steel or aluminium alloy

b. Pressure control valves (PCV),
c. Hydrostatically tested pumping circuits for refuellers,
d. Externally mounted emergency stop buttons for engine and refuelling.
e. All refuellers shall carry only one grade of product and the grade identification shall be
displayed prominently on the control panel.
f. Main product piping shall be equipped with low point drain plugs located so as to enable
complete draining of all product.
g. All pipe work and accessories shall be of aluminium alloy, stainless steel or mild steel
protected internally by hot tinning or by lining with epoxy material, approved as being
compatible with aviation fuels.
h. No copper alloys, cadmium plating, galvanised steel or plastic materials shall be permitted
for main piping. The use of copper containing materials for other components in contact with
ATF should be avoided and no zinc, magnesium or cadmium shall be used.
i. Spill Containment kit: it is recommended that all fuelling equipment be equipped with a
spill containment kit for use as first response to a spill on the apron. The contents of the
kit should comply with local airport regulations and include fuel absorbent pads.
ii. Sealing System: Suitable seals shall be provided on Fire extinguishers, nozzles, Meters.
To be provided on Deadman override, Interlock override, wherever provided.
iii. All refuelling Equipment shall have Flame arrestor (Approved by Petroleum and
Explosive Safety Organization) fitted on the outlet of the exhaust system of the vehicle.
i. New generation refuelling vehicles shall be fitted with a brake interlock system to prevent
drive away, roll away and jet blast blow away during fuelling of aircraft. This system shall be
activated whenever hose couplings (including hydrant inlet couplings), platforms, bonding
reel, platform railing are removed from their normally stowed positions. The system will be so
designed that no operator action (such as engaging the handbrake) is required to arm and/or
activate the interlock mechanism. Emergency interlock overrides shall be safety wired and
sealed in the interlock operating position. The sealing wire shall be easy to break in an
emergency. Interlock status warning indicator light will indicate whenever an interlock
protected component is removed from its stowed position. An emergency override status
warning light which indicates whenever the override mechanism is moved from its normal
operating position shall be fitted in a prominent position in the cab.
j. Overwing (trigger) fuelling nozzles shall not have hold-open ratchets. Overwing fuelling
nozzles shall be grade marked and colour coded (black for Jet A-1). Nozzle spouts shall not
be painted or coated. Brake interlock to be extended to the overwing nozzle.
k. All refuelling equipment (hydrant servicers and Refuellers) shall be fitted with pressure
control systems to protect aircraft from excessive flow and shock pressures (surge) which
can damage aircraft fuel systems. The pressure control equipment shall be of a type and
design which has undergone a formal approved test procedure. The minimum requirements
for pressure control equipment are as follows:
i) Maximum achievable pump/hydrant pressure below 3.5 bar (50 lbf/in2) : Not required.
ii) Maximum achievable pump/hydrant pressure 3.5 to 5.5 bar (50 to 80lbf/in2): Hose End
Pressure Control Valve required. In-line Pressure Control Valve required for vehicles with
maximum flow rates of 1000 litres/min or more per delivery hose.
iii)Maximum achievable pump/hydrant pressure above 5.5 bar (80lbf/in2): Hose End
Pressure Control Valve and In-line Pressure Control Valve required.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Other features:

I. Hose End (Primary) Pressure Control Valves are situated at the nozzle at the end
of the delivery hose. In-line (Secondary) Pressure Control Valves are situated on the
vehicle, in the inlet coupler (hydrant servicer). A second Hose End Pressure Control
Valve is acceptable in place of an In-line Pressure Control Valve, provided that the
maximum inlet pressure does not exceed 8 bar (115 lbf/in2).
II. Fire Extinguishers
All fuelling vehicles and trailers shall carry at least 2 nos 9/10 kg (unless a different
size is specified by local legislation) dry chemical type fire extinguishers in quick
release housings consistent with local regulations and 1 no. 1 Kg CO2 type fire
extinguisher shall be provided in the driver’s cabin..
III. Bonding Reel and Cable
A bonding reel and cable with suitable clip shall be provided, electrically bonded to
the vehicle chassis.
IV. Emergency Engine and Fuel Stop Control: Externally mounted emergency engine
stop and fuel stop controls shall be provided and shall be clearly identified.
V. Deadman Control System
All pressure fuelling vehicles shall be fitted with a deadman control system. New
generation deadman control system should be designed to require periodic action by
the operator within a pre-determined time interval to prevent automatic close-down. In
hydrant systems the deadman control shall, where possible, activate valve closure
upstream of the hydrant servicer inlet hose. Deadpan systems include an override
switch. This is for operation only in emergencies. It shall be sealed in the non-by-
passed position.
VI. Placards on vehicle:
The following placards shall be available on any Refuelling Equipment.
a. Hazchem sign (for refuellers)
b. Product ID
c. No smoking
d. Interlock light
e. Override light
f. Emergency shut-off
g. Clear Exit
h. Mobile not allowed.
l. Refuellers Tank
i) All Refuellers tanks shall be either constructed of mild steel internally coated with a light
coloured epoxy material (approved as being compatible with aviation fuels) or of aluminium
alloy or stainless steel. The tank shall be designed as a single compartment with baffles as
per PESO.
ii) The tank shall drain to a low point sump, provided with a drain line and valve. Single
compartment tanks are preferred, but if multi compartment tanks are used, then each
compartment shall have separate drain lines not manifolded together. All drain lines shall
have a constant downward slope.
iii) Tanks shall be provided with adequate venting to take care of rated loading/unloading flow
rates.
iv) All Refuellers shall be bottom loaded through a self-sealing (tight fit) connection.
v)The main outlet from the tank shall be fitted with an internal foot/bottom valve capable of
being shut quickly in an emergency.

m. Elevating Platforms for Hydrant Dispensers, wherever provided for operational

convenience:
Elevating fuelling platforms shall be equipped at least with:
i) Emergency Engine and Fuel stop controls
ii) A safe exit route when the platform is in the fully raised position or an emergency lowering
capability that can also be operated from ground level. In the space of a hydraulic system the

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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depressurisation line should be dedicated to this function and be routed direct to the oil
reservoir, not via filter
iii)A suitable device to prevent contact with the aircraft during raising the platform should be
provided.
n. Lanyards for Hydrant Dispensers
i) Lanyards for hydrant pit valve operation shall be manufactured from fire resistant material of
adequate strength (for example, cord with steel heart strands).
ii) It is recommended that lanyards are of a highly visible colour such as red. The selected
colour should be in line with any local regulations concerning the recommended colours for
emergency systems and shall be different to that of the fuelling vehicle bonding cable. There
should be no electrical connection between the fuelling vehicle and the hydrant pit. If lanyards
are attached to vehicle-mounted reels, the reels should be electrically isolated from the
vehicle.
8.9.2. Refuelling Operations:
8.9.2.1. Tarmac Safety:
i. When the aircraft parking position is known, the refuelling equipment and crew shall proceed
to the fuelling area, for refueling the aircraft, when it arrives. The vehicle brakes should be
checked before approaching the aircraft. Strictly follow all the apron safety rules and
regulations specified by the local airport authority.
ii. Fuelling of aircrafts shall only be done outdoors and not less than 15 meters away from any
building.
iii. Refuelling equipment shall be operated carefully on the periphery roads and apron and speed
shall not exceed the approved limits for the airport. If the speeds are not specified at any
airport, the following speeds maybe taken into consideration:
a. On the periphery roads : 30 kmph.
b. On the Apron : 15 kmph.
c. Approaching aircraft : 5 kmph.
iv. The use of a mobile phone whilst driving a fuelling vehicle is strictly prohibited. Calls shall not
be made or received whilst driving.
v. Vehicles shall not approach aircraft until the aircraft anti-collision lights have been switched
off.
vi. The approach to an aircraft shall be such that in the event of the vehicle’s brake failure,
collision will be avoided.
vii. The order of arrival of support equipment is generally prescribed by the airline, with the stairs
or aerobridge being positioned first. Refuelling equipment shall arrive strictly on time in order
to avoid congestion and the possibility of fuelling delays. This is particularly important for large
refuellers, which require a substantial area for manoeuvring.
viii. Wherever possible, refuelling equipment should be moved in a forward direction. If moving a
refuelling equipment in reverse is necessary in an emergency, guides (crewman/supervisor or
assistance from airline) shall be used.
ix. Vehicles shall be positioned safely, taking account of the following:
a. Extreme care should be taken to avoid the possibility of collision with any part of the
aircraft or ground servicing equipment whilst manoeuvring in to(and away from) the
fuelling position.
b. Fuelling staff shall ensure that clear path is maintained to permit rapid removal of
fuelling equipment in case of emergency. While placing the Refuelling equipment
oblique approach to the aircraft shall be followed. The refuelling equipment shall
never be reversed towards the aircraft.
c. Vehicle delivery hoses and hydrant servicer inlet hoses should be positioned to
minimise the risk of baggage handling equipment or other aircraft servicing vehicles
driving over them and causing damage.
d. If underwing deck hoses are to be used, it must be possible to connect hoses to the
aircraft fuelling point without exerting any sideways pressure which could damage the
aircraft adapters. Once connected, hoses should hang freely and vertically from the
fuelling point.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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e. Special precautions shall be taken to ensure that vehicles used for underwing fuelling
have sufficiently low profile for this purpose.
x. If possible, avoid any part of vehicle being in line with aircraft engine exhaust ensuring that
deck hoses can hang freely and vertically (without sideways pressure) from the aircraft
adaptors.
xi. Due allowance should be made for settlement of the aircraft wing and other surfaces under
increased fuel load in positioning the fuelling vehicle. If possible, the engine of the fuelling
vehicle should not be positioned under the wing of the aircraft.
xii. Under normal circumstances the fuelling equipment shall be positioned to allow a clear
forward drive out in an emergency and to permit ready movement to another aircraft when
fuelling is complete.
xiii. When in position, the operator of the refuelling equipment shall not leave the cab until the
parking brakes have been applied.
xiv. While raising the lift platform of a dispenser, care shall be taken to ensure that it does not
touch any part of the aircraft.
xv. Operating staff shall be wearing PPE like safety shoes, bump cap/helmet, high visibility
jacket, gloves and ear protection while refuelling.
xvi. Place the traffic cones in position for segregating the refuelling area
xvii. Carry soak mat (spill containment kit) with vehicle.

8.9.2.2. Underwing Refuelling with Hydrant Dispenser:

Promptly after the dispenser has been positioned for the refuelling as detailed above, the
following operations shall be performed in sequence:
a) When the equipment has been positioned properly, the operator shall activate the
handbrakes and place chokes under front and rear tyres.
b) An earthing plate should be securely placed under the vehicle tyre.
c) Fire extinguisher to be unclamped or kept at panel side of the Refuelling Equipment at an
easily accessible position.
d) Unreel and securely connect the bonding reel wire to a designated point on the aircraft. If
no point is designated, select a point (preferably with the assistance of the aircraft operator)
which is bare metal but not to:
i) Any part of a wheel assembly (there may be no continuity to the rest of the aircraft);
ii) Any radio antenna;
iii) Any polished, sliding or stressed components such as under carriage details, flap
tracks or propellers. Suggested components suitable for bonding include the lip around
many fuelling panel access doors or other similar apertures. This should however be
done only after obtaining the clearance from the aircraft engineer.
e) Connect delivery hoses to aircraft. Ensure that the bonding of the nozzle to the aircraft is
done before the nozzle is connected to aircraft adaptors. Open the nozzle valve. Ensure that
the opening lever handle is in the over centre position. Check that the connection to the
aircraft adaptor is secure by attempting to remove the nozzle with the nozzle handle in the
locked position.
f) Remove the hydrant pit cover and remove any dirt or water on adapter surface.
g) Attach lanyard to hydrant pit valve and extend lanyard towards the operating position and
clear of obstructions. Ensure that the pit valve is closed by activating the lanyard to close the
pit valve.
h) Connect intake hydrant coupler to pit valve. Do not actuate hydrant pit valve until fuelling is
to start. Place the traffic cones in position for segregating the area.
k) Note and record accurately all meter totalizer readings. Wait for airlines representative for
opening manual fuelling valve on aircraft, if provided.
m) QC Check to be performed on the line sample drawn from the outlet of the filter monitor
vessel or filter water sump. When an Airline representative advises that delivery can start,
open hydrant pit valve and actuate deadman control to start flow;

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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n) If so requested by the airline, after start of flow to aircraft; approximately 1000 litres will
ensure most dispensers have been flushed of fuel from the previous delivery before taking the
sample.
o) The showing of the sample and microdetector capsule check results to the airline
representative is desirable to facilitate the acknowledgment of acceptance of a water and
particulate free delivery in the Aircraft Delivery Receipt (ADR).
p) Hand hold open deadman control throughout fuelling and maintain a clear view of the
dispenser control panel and aircraft fuelling points. Where deadman timers are installed, the
deadman should be actuated in frequency with the setting to avoid interruption to the fuelling;

Note: All the Electrical deadman systems include a deadman override. This should be
preferably of the spring loaded, push button type. In case no spring return deadman override
switches are used the same need to be properly sealed in the inoperative position at all times
other than for emergency use. Whenever used during refuelling, it should be continuously
attended by a refuelling operator/supervisor. Preferably, all deadman override switches
should be converted to push button type. Deadman override switch should be used only for
completing the ongoing refuelling and the deadman should be repaired before it is taken for
the next refuelling.
a) During fuelling, occasionally check the vehicle, inlet and all delivery hoses for
leaks, aircraft fuel vents for overflow and monitor the dispenser gauges for operation
within limits, particularly the differential and fuelling sense pressures. Record the Inlet
pressure, Nozzle Pressure, differential pressure and the flow rate of the refuelling
when the differential pressure is noted. Be alert to and respond to instructions from
the airline representative, or to situations requiring emergency action; If the fuelling
sense (venturi) pressure is greater than the maximum indicated on or adjacent to the
aircraft gauge (limits for the same is 50 psi unless a lower limit is prescribed for the
aircraft)while fuel is flowing, the fuelling should be stopped since the secondary
pressure controller (the Pressure Control Valve) is apparently no longer able to limit
steady flow pressure to a level which is safe for the aircraft.
b) On completion of fuelling and after confirmation from airline representative, close
hydrant valve and accurately record meter totalizer readings and delivered quantity.
c) Disconnect nozzles and attach dust covers; retrieve hoses and securely stow
nozzles in holders. Do not remove ladder or lower lift platforms until airline
representative has completed his check of the adapters, etc. and has completed
panel work.
d) Before removing dispenser on the completion of the fuelling, perform a final check ,
including a complete “360 Degree” walk around the vehicle to ensure that the aircraft
fuel caps have been refitted, that the fuelling vehicle is properly disconnected from
the aircraft and that all equipment are stowed correctly. Ensure that all hoses are
properly stowed and that lift platform and rails are fully retracted. Disconnect and
retrieve bonding and grounding wires and ensure that no items are left behind.
e) Drive dispenser off moving in a forward direction. If reversing is necessary due to
congestion, the concurrence of the airline staff should be taken. Equipment should be
properly guided out of its position.
f) In case the brake interlock and Deadman override seal is broken in emergency
situation or any other defect/abnormality is observed in equipment during refuelling,
the information shall be recorded in Log Book.

8.9.2.3 Underwing Refuelling with Refuellers:

Promptly after the refuellers has been positioned for the refuelling as detailed earlier,
the following operations shall be performed in sequence:
a) When the equipment has been positioned properly, the operator shall activate the
handbrakes and place chokes under the tyres. Place the traffic cones in position for
segregating the refuelling area
b) An earthing plate should be securely placed under the vehicle tyre.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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c) Fire Extinguisher to be unclamped or kept at panel side of the Refuelling

Equipment at an easily accessible position.
d) Unreel and securely connect the bonding reel wire to a designated point on the
aircraft. If no point is designated, select a point (preferably with the assistance of the
aircraft operator) which is bare metal but not to:
i) part of a wheel assembly (there may be no continuity to the rest of the aircraft);
ii) any radio antenna;
iii) any polished, sliding or stressed components such as undercarriage details,
flap tracks or propellers.
e) Suggested components suitable for bonding include the lip around many fuelling
panel access doors or other similar apertures. This should however be done only
after obtaining the clearance from the aircraft engineer.
f) Connect delivery hoses to aircraft. Ensure that the bonding of the nozzle to the
aircraft is done before the nozzle is connected to aircraft adaptors. Open the nozzle
valve. Ensure that the opening lever handle is in the over center position. Check that
the connection to the aircraft adaptor is secure by attempting to remove the nozzle
with the nozzle handle in the locked position. Return all meter registers to zero, note
and record accurately all meter totalizer readings. Do not use totalizer readings from
previous delivery.
g) Wait for airlines representative for opening manual fuelling valve on aircraft, if
provided.
h) QC check to be performed on the line sample drawn from the tank bottom and
outlet of the filter monitor vessel or filter water sump. When airline representative
advises that delivery can start, engage pump, open flow valves and actuate deadman
control to start flow. Gradually advance engine speed control to the desired flow rate
if this function is not automatic;
i) Perform quality control checks on line sample drawn downstream of the filter water
separator or filter monitor before commencement of refuelling.
j) The showing of the sample and microdetector capsule check results to the airline
representative is desirable to facilitate the acknowledgment of acceptance of a water
and particulate free delivery in the Aircraft Delivery Receipt.
k) Hand hold open deadman control throughout fuelling and maintain a clear view of
the refuellers control panel and aircraft fuelling points. Where deadman timers are
installed, the deadman should be actuated in frequency with the setting to avoid
interruption to the fuelling;
Note: All the Electrical deadman systems include a deadman override. This should
be preferably of the spring loaded, push button type .In case no spring return
deadman override switches are used the same need to be properly sealed in the
inoperative position at all times other than for emergency use. Whenever used during
refuelling, it should be continuously attended by a refuelling operator/supervisor.
Preferably, all deadman override switches should be converted to push button type.
Deadman override switch should be used only for completing the ongoing refuelling
and the deadman should be repaired before it is taken for the next refuelling.
l) During fuelling occasionally check the vehicle and delivery hoses for leaks, aircraft
fuel vent for overflow and monitor the fueller gauges for proper operation within limits,
particularly the differential and fuel sense (nozzle) pressures. Be alert and respond to
instruction from the airline representative or to situations requiring emergency action;
Adjust engine speed as required by delivery conditions;
m) On completion of fuelling and after confirmation from airline representative,
disengage pump and accurately record meter totalizer readings;
n) Disconnect and retrieve bonding and grounding wires and ensure that all hoses
are stowed and that no items are left behind. Before removing the refuellers at the
completion of the fuelling, ensure, perform a final check, including a complete “360
degree” walk around the vehicle to ensure that aircraft fuel caps have been re-fitted,
that the fuelling vehicle is properly disconnected from the aircraft and that all

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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equipment is stowed correctly. Ensure that all hoses & ladder are properly stowed.
Disconnect and retrieve bonding and grounding wires and ensure that no items are
left behind
p) Drive refuellers off moving in a forward direction; if reversing is necessary due to
congestion, the assistance of guide shall be obtained.
u) In case the brake interlocks or Deadman Override seal is broken in emergency
situation or any other defect/ abnormality is observed in equipment during refuelling
the information of same shall be recorded in Log Book.
8.9.2.4. Overwing Fuelling:
The following special precautions shall be adhered to for overwing fuelling:
a) For refuelling attended by the flight crew or aircraft operator, ensure there is a fuel
grade decal or other sign writing around or adjacent to the aircraft fill aperture to
identify clearly the grade of fuel to be used in this aircraft. It shall be ensured that
details are received in writing with due endorsement from the airline representative as
per Refuelling Request Format.
b) If there is no grade marking on the aircraft or if it is a non-scheduled flight,
refuelling shall not commence until a Refuelling Request Format, reconfirming the
grade of the fuel required has been filled/completed, by the airline
representative/operator.
c) If it is necessary to climb onto any part of the aircraft to gain access to fill points, do
not wear footwear with protruding nails or studs since these may cause damage to
the wing surface of the aircraft.
d) Do not carry loose items such as pens, pencils or loose change in the pockets of
shirts or jackets since these may fall into the aircraft tanks;
e) Ensure the grade of fuel is correct for the aircraft. Nozzle spouts used for fuelling
jet aircraft must be of the flattened type with a major axis dimension of at least 67mm
to prevent misfuelling of aircraft requiring Avgas. However, a few jet aircraft have
apertures too small to accept a 67mm dimension and some AVGAS aircraft have
apertures large enough to accept 67mm nozzles. It is therefore essential to have the
Refuelling Request Format duly filled before the commencement of the refuelling.
f) Ascend, if applicable, to the wing top area from the wing leading edge. Take care
not to step or walk on prohibited wing areas, particularly the trailing edge or flaps;
g) Use ladders with padded ends and use mats to protect wing leading edges;
h) Do not route hoses over trailing edges;
i) Position hose on the ladder, not alongside. Ensure that mats protect wing edge
from hoses.
j) On all aircraft fuelled with overwing nozzles, it is necessary to avoid:
I) Mechanical damage to the floor of the aircraft tank from:
i. Having a nozzle spout of excessive length or
ii. Having an excessively powerful jet of product from the nozzle;
II) Static electricity build up from splash filling, this shall be prevented by ensuring that
the end of the nozzle used for a particular aircraft reaches within a few inches of the
floor of the aircraft tank or the surface of product already in the tank or filling takes
place at reduced flow until the end of the nozzle is covered by product;
k) Check that overwing nozzles do not include ratchet lugs or other mechanical
devices to hold nozzle open. Overwing nozzles shall not be wedged open under any
circumstance;
m) Bond the overwing nozzle to the aircraft if this is possible before removing the fill
cap. Maintain bonding until the cap is replaced;
n) Adjust the fuelling rate to meet the aircraft operator’s specified conditions provided
the operator’s requirements do not conflict with the procedure in this manual;
o) Have available a clean waterproof tarpaulin to cover nozzle and fill opening during
rains or thunder storms. Do not use a chamois leather or any other type of strainer at
the aircraft fill opening when fuelling jet aircraft. In wet or dusty conditions, it may be
necessary to block the gap between the nozzle and filler orifice with a clean, lint-free
cloth made from natural fibres;

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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p) Maintain close coordination with airline representative at fuelling panel gauges

8.10. SAFETY IN DESIGN OF HYDRANT REFUELLING SYSTEM:

a) No electrical connection between the fuelling vehicle and the hydrant pit. If lanyards are
attached to vehicle-mounted reels, the reels should be electrically isolated from the vehicle.
b) All new hydrant pit valves shall be as per EI1584 specifications. These must be compatible
with hydrant servicer intake couplings.
c) Hydrant lines should preferably be internally epicoated. Before being put into operation, they
shall be cleaned by flushing with the product, which the line will eventually carry, until all
traces of rust and other impurities completely disappear from samples drawn at delivery
points.
d) Hydrant pit valves should have isolation valves.
e) All the hydrant systems shall be provided with equipment that allows the fuel flow to be shut
down quickly in an emergency. The preferred hardwired fixed system consists of Emergency
Stop Buttons which, when activated, shut down the hydrant pumps (and valves where the
pressure head results in continued fuel flow with pump shut down.)
f) Emergency Stop Buttons (ESBs)/Emergency Shut Down (ESD) shall be located close
(maximum 80 meters) to fuelling bays.. They shall be clearly identified and easily accessible.
High visibility identification signs, emergency instructions should be mentioned such that they
remain visible at all times.
g) All hydrant pit covers shall be tethered or permanently connected to pits to prevent them from
being picked up by jet blast.
h) All hydrant low point drains shall be clearly identified.
j) All hydrant pits, high and low points and dead end points shall be numbered clearly. These
facilities should be located at a minimum distance of 4.5 m from any other hazard.
k) Larger hydrants should be split into sections, which can be isolated for emergencies and
testing and repairs. Isolation should be by Gate Valve or double block and bleed valves
(DBBV).
l) Colour Coding & Identification:
All colour coding shall be in line with Aviation Quality Control and Assurance Manual. All pipelines
leading to or from tanks, fittings such as valves/flanges, filters, strainers, delivery/discharge hoses,
etc. shall be properly colour coded to the grade of fuel to which they are dedicated.

8.11 SAFETY IN AIRCRAFT REFUELLING OPERATIONS:

Driving inside the airport:

Driving inside the airport needs certain discipline. The airport rules are to be followed at all times
and importance should be given to the local airport regulations. However, the following driving rules
may be taken as guidelines and followed if not contravening the local airport regulations:

a) Right of way shall always be with the pedestrians and aircraft.

b) The vehicle shall pass to the rear of the aircraft.
c) Apron speed limits shall be adhered to.
d) Speed shall be reduced at intersections, in congested areas, on wet roads/ apron surfaces or
when visibility is reduced.
e) The vehicle shall be halted before crossing any runway and the clearance from the ATC/ pilot
vehicle is taken before crossing.
f) All road signs such as ‘STOP’,“NO PARKING” shall be observed.
g) A minimum distance of roughly one vehicle length shall be maintained from the vehicle
ahead.
h) Necessary signals shall be given when turning left, right or stopping.
i) Double parking, or parking in the opposite lane of drive shall be avoided. Vehicles shall be
parked sufficiently away from any intersection, if required.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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j) If required to park the vehicle adjacent to the runway. It will be parked parallel to the runway at
least 75 feet outside the runway boundary lights.
k) When approaching other vehicles or taxiing aircraft, the headlight beams shall be dipped.
l) Traffic lanes shall be followed as far away as possible from the parked aircraft.
m) Before the aircraft enters the parking ramp area, vehicles shall be parked in a position outside
the minimum space envelope as decided by the airline officials.
n) Vehicles shall be moved into position only after the aircraft has come to full stop and all engines/
propellers stopped.
o) Vehicles shall not be driven under the wings of an aircraft except with the permission of the
responsible representative of the airline concerned and/or airport manager.
i. When approaching or leaving the aircraft, the vehicle shall be manoeuvred slowly and
carefully, taking care not to drive across lanes leading to passenger loading gates.
ii. The vehicle shall be positioned near the aircraft in a long sweeping single approach in the
forward direction, avoiding any manoeuvring.
r) At the sound of an emergency alarm, the moving vehicle shall be parked in a safe position,
except when responding to an emergency. The vehicle shall be moved out such that it is not in
the emergency area or in the path of the emergency equipment.
a. Maximum speeds while driving fuelling equipment on a normal dry surface shall be as
given below:
i) Peripheryroad:30km/hr
ii) Transiting ramp: 15km/hr
iii) Approaching aircraft: 5km/hr

Safety during Refuelling:

I. Positioning of fuelling equipment around aircraft shall be resolved with the local airport and
airline authorities. The most suitable position is as near as possible to the fuelling points of
the aircraft. The unit shall be parked in such manner as to prevent any of the aircraft
surfaces from bearing on the fuelling unit. Fuelling staff shall ensure that clear path is
maintained to permit rapid removal of fuelling equipment in case of emergency.
II. After parking, the driver shall not leave the cabin until the Handbrake is on and in locked
position and the wheel chocks placed in position.

III. The front wheels are to be turned in a direction so as to permit the equipment to be driven
out away from the aircraft, without further guidance.

IV. The driver shall not leave the unit unattended, with the engine running.
V. If the truck has to be left unattended on the ramp for work other than that associated directly
with fuelling, the driver shall:
a. Stop the engine.
b. Place hand brake in “ON” and “LOCKED” position.
c. Check brake air pressure.
d. Chock the tractor drive wheels with a wedge block to ensure absolute firmness.

VI. During fuelling the following precautions shall be observed:

a. “NO SMOKING” and “NO USE OF MOBILE PHONES” sign shall be prominently
displayed.
b. Fuelling shall only be done outdoors and not less than 15m from any building.
c. Use of appliance employing naked flame, or any means of igniting the fuel vapour shall
not be permitted within 30m of the aircraft/fuelling equipment.
d. Aircraft and the fuelling equipment shall be bonded to each other.
e. Fuelling operations shall cease when a turbo-jet aircraft manoeuvres so as to bring the
rear jet blast within 50m of the fuelling equipment or the aircraft fuelling point and vent
system.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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f. Fuelling of aircraft shall be avoided during severe storm.

VII. Spills & Leaks:

Fuelling equipment with leaks of any type shall be removed from service and not operated until
properly repaired. Fuelling personnel shall be alert to hose failure or other causes of fuel leaks.
Small fuel spills (less than two (2.0) square metres) require no emergency action. Spills covering
an area greater than two (2.0) square metres are more hazardous and the following action shall
be taken:
a. Stop the fuel flow and close the hydrant valves by operating the lanyard and/or deadman
control;
b. In the event of a delivery hose breakage or spills originating at the underwing coupler or
upstream of a pressure control valve, stop the flow at the dispenser by operating the
deadman or other flow shutdown device and, if possible, close the delivery nozzle or aircraft
valves;
c. If an intake hose fails, shut down the flow at the hydrant pit and then at the dispenser;
d. Evacuate people from the area of the spill;
e. Post a refuelling operator/crewman fireguard around the spill equipped with at least one
(1) 9/10kg dry chemical fire extinguisher; prevent movement of people or vehicles in the
vicinity of the spill to reduce risk of ignition;
f. Cover the spill with sand, dry earth or an absorbent material and contain the fuel to prevent
its entry into the airport drainage system. After clean up, remove the fuel soaked material to
a safe place for disposal;
g. If a spill is over five (5) square metres in area, or where fuel continues to flow, promptly
notify the airport fire service and the nearest airline representative;
h. Do not resume operation until the fuel spill has been cleaned up and the area is safe;
i. Investigate every fuel spill to determine its cause, and to evaluate the effectiveness of the
clean-up operation.
j. Ensure to comply with any more stringent airport authority regulations which may exist.
k. In no circumstances shall samples be disposed of on the ground.

8.12 SAFETY FEATURES IN HYDRANT REFUELLING SYSTEMS:

Fuel is delivered under pressure to the fuel hydrant system from the airport fuel station, via a fixed
pipe work installation, which is normally buried, to hydrant pits located at each aircraft fuelling
position. These fuelling positions are usually located in the aprons. The aircraft is fuelled by means of
one, or in some cases two, hydrant servicer vehicles. These are connected by flexible hose(s) to the
hydrant valve(s), located in the hydrant pit(s), and the aircraft fuelling adaptor(s). Hydrant servicers
are fitted with filtration, pressure regulation and metering equipment and are designed to provide the
required high standard of quality control, safety and efficiency which should attend all aircraft fuelling
operations. The system should be designed to ensure that fuel may be delivered at the aircraft
coupling at the required pressure and flow rate.

8.12.1 Hydrant pipelines should be sized to handle the fully developed peak design capacity of the
system at flow velocities that would not generate unacceptable surge pressures in the event
of rapid and simultaneous closure of aircraft tank valves. However, the correct sizing of pipes
is but one factor in the design of a safe and efficient hydrant system which must be
considered in conjunction with site levels, the product(s) to be handled, the operating
temperature range and the design characteristics of all items affecting pressure and flow,
including;

a. Tanks;

b. Pumping sets;

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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c. Automatic control systems;

d. Filtration equipment;

e. Hydrant pit valves;

f. Shock alleviators;

g. Hydrant servicers (pipe systems and components), flexible hoses; and

h. Aircraft fuel systems (pressure and flow rate limitations).

8.12.2. Cathodic protection

Cathodic protection meeting local or national standards should be installed to prevent the
corrosion of underground pipeline systems feeding fuel to hydrants.

8.12.3 External coating of pipeline

When CS pipes are installed below ground they should be appropriately protected against
corrosion. The following are the preferred methods:

a. Factory applied epoxy resin coating.

b. Bituminous primer paint and self-adhesive plastic wrapping.

c. Factory applied polyethylene coating.

Joints made during installation should be protected by an appropriate wrapping system. The
integrity of the external coating and wrapping of buried pipes should be verified, and any
defects corrected before the trenches are backfilled; great care should be taken to protect the
wrapping during back filling.

8.12.4 HYDRANT PITS:

Hydrant pits are positioned in the areas where aircraft are parked and they should embody
the features described in a) to e) below:
(a) Pits should be capable of accommodating the equipment detailed in 8.12.5.
(b) Pits should be provided with suitable flush fitting covers sealing against rainwater. The design
of covers should be such that they can be safely lifted by one person. Materials used for pit
covers should not produce sparks when struck. Covers should be hinged to pits to prevent
them being carried away by jet blast or propeller vortex. Pit boxes, where riser pipes enter,
should be adequately sealed to prevent water entering from below and to prevent any fuel
from seeping into the ground. Where there is more than one system in an airport, covers
should be provided with a suitable plate to identify the name of the owner/operator and the
grade of fuel. If the pit box is fitted with a hinged lid, the lid should be so orientated that, when
open, it does not cause the lanyard to become snagged.
(c) High loadings can be imposed on hydrant pit boxes from aircraft wheels, tugs, other service
vehicles or from settlement or movement of adjacent aprons. To prevent transmission of
these loadings to hydrant risers (to which the hydrant pit valve is fitted, each hydrant pit box
should be effectively isolated from its hydrant riser by means of a sealing arrangement that
can accommodate both lateral and vertical differential movement.
(d) Pits should be installed so that they project at least 25 mm (1 inch) above the apron level to
prevent the entry of surface water. Concrete surrounds should be ramped up at a gradient
0 0
between 3 and 5 to the top of pits.
(e) Isolating valve should be installed between the riser flange and the hydrant pit valve. (as per
rd
API/EI 1584 3 Edition)

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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8.12.5 HYDRANT PIT VALVES:

(a) Hydrant pit valves should be of the ‘quick release’ type designed to close at a controlled rate
so that during closure the build-up of shock pressure in the hydrant line is minimized.
(b) As a minimum, the pilot device controlling the operation of the valve should be fitted with a
manual means of opening and closing, the closing action being made possible by pulling on a
lanyard. However, an air-operated pilot device to be installed with the pit valves.
(c) The lanyard should always be of fire-resistant material of adequate strength to enable the
valve to be operated remotely should an emergency occur during the fuelling operation and
should preferably be red in colour.
(d) Where a dual closure device is provided, the air-operated pilot device should be fitted with a
lanyard. (as per latest API/EI 1584).
(e) A self-sealing male adaptor with tethered dust cap should be incorporated in the hydrant pit
valve outlet to which the female coupling of the hydrant inlet hose is attached. It should be so
designed that the hydrant hose can be connected or disconnected without spillage of fuel.
(f) Hydrant pit valves should be fitted API standard hydrant pit outlet adaptors. The hydrant pit
assembly arrangement should conform to API/EI 1584.

8.12.6 EMERGENCY SHUT DOWN (ESD) CONTROLS:

Because of the nature of aircraft fuelling operations and the distance between the pumps in the
airport fuel depot and the fuelling location, it is essential to have a safe system to shut down the
flow of fuel in an emergency. Details provided in Clause 8.10 (f). Hard wired systems have been
preferred but new technologies exist that do not require, hard wiring. Regardless of the system
used, it should be reliable.

8.13 SAEFTY IN BARREL OPERATIONS:

8.13.1 Receipt of Aviation Fuel in barrels:

The normal packages used to transport Aviation Fuels are the drums with 200/210 litres
capacity. The loading location must comply with the quality control and safety
requirements, while loading and transporting the stocks in drums.

The stocks in drums are transported in trucks. While unloading the drums, enough care
should be exercised, to ensure that the drums are not damaged. It is recommended to
stack old unserviceable tyres below the drum unloading point. The drums should be
unloaded using an unloading ramp. The drums should be stacked in the place earmarked
for this purpose. All drums carrying “DP” products shall be stacked in DP shed. It shall be
ensured that the license of the DP shed is valid and the storage does not exceed the
authorised capacity.

8.13.2 Storage:

For each consignment, placard indicating the grade of product, Batch No. and date of
Test Report shall be exhibited.
Each consignment shall be stacked separately to facilitate delivery of stocks on first in
first out basis.
All the barrels when stored shall be kept only in sealed condition.
The barrels shall be visually inspected at least once in a day for any leaks and the
observations recorded in the shift log. During monsoon, adequate precautions shall be
taken to prevent ingress of water into the drums. When drums are stored in the open

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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over dunnage with a tarpaulin cover, the water stagnated over the tarpaulin cover shall
be removed on priority.

8.13.3 Loading of Barrels:

There are certain occasions at an AFS when the loading of barrels are undertaken for
delivering packed fuel stock. Following procedures shall be followed.
The barrels shall be selected in the following order of priority:
i. New Barrels.
ii. Barrels having stored similar aviation fuel previously
iii. Once used PBM barrels
Lube oil/Black oil drums shall not be selected for filling Aviation fuel.
The drum-filling operations shall be taken up only in the licensed area.
Before flushing, it should be ensured, that each drums is clean and dry.
Each barrel shall be flushed with a minimum of 5 litres of the grade to be filled or till
such time, a clear and bright sample is obtained. The flushed quantities shall be
downgraded to a similar non-aviation grade.
The electrical bonding connection shall be established between the filling nozzle and the
barrel. In the case the drums are filled over a wooden platform instead of ground proper
bonding connection shall be established between the drum and the filling source.
While filling, it shall be ensured that 5% of the capacity of the container is left as vapour
space for safety reasons.
The barrels shall be sealed tight, using bungs with washers.
It shall be ensured that the barrels are stacked in a vertical position in a single tier in the
truck properly covered with tarpaulin.
Fire extinguishers of adequate capacity shall be carried along with the drums.
Before filling the containers of the customer, it shall be ensured that the customer
furnishes a certificate that the product shall be used for bonafide aviation use.
The Explosives License authorising the customer to transport and store the fuel shall also
be produced before requesting for fuel.
The filling of container shall be taken up only after satisfying conditions mentioned
above.
The quantity to be delivered shall not exceed the quantity indicated in the license.
All the precautions and procedures given above shall be adhered to. Containers not fit
for Aviation use shall be rejected.
The flushed quantities shall be collected in a drum and downgraded to a similar non-
aviation grade. However, this downgrade product shall not be handed over to the
customer.

8.13.4 Refuelling of aircrafts from barrels:

All safety precautions as in the case of a refuellers shall be taken before undertaking
refuelling.

Filling of TT/refuellers from barrels:

All precautions and procedures as stated above shall be followed while filing a tank truck
or a refuellers from drum stock.

8.13.5 Disposal of empty barrels:

Avgas is now being received in barrels & once the barrels are empty, they need to be
handled in a special way as Avgas is highly volatile. If not handled properly, the vapour

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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of empty barrels may catch fire. Therefore, it is advised that the following Safety
procedure is to be followed:

1. Fill empty Avgas barrels with water.

2. Empty out.
3. Dispose off/store.

9 FIRE PROTECTION FACILITIES

Salient features of Fire Protection Facilities for AFS:

9.1. GENERAL CONSIDERATIONS

The size of product storage and handling facilities, their location and terrain determine the basic fire
protection requirements.

9.2. FIRE PROTECTION PHILOSOPHY

The fire protection philosophy is based on loss prevention & control. It considers that an AFS carries
an inherent potential hazard due to flammable nature of petroleum products stored therein. A fire in
one facility can endanger other facility of the AFS, if not controlled / extinguished as quickly as
possible to minimize the loss of life & property and prevent further spread of fire.

9.2.1 FIRE PROTECTION

Depending on the nature of risk, following fire protection facilities shall be provided in AFSs with
above ground aggregate storage capacity of more than 1000 KL.

a. Fire Water System -(storage / pumps / distribution piping network with hydrant / monitors)
b. Fixed Spray System
c. Foam System.
d. First Aid Fire Fighting Equipment.
e. Trolley mounted/Mobile Fire Fighting Equipment.
f. Carbon Dioxide System.
g. Dry Chemical Extinguishing System
h. Fire Alarm, Actuation & Communication System.

For AFSs storing less than & equal to 1000 KL aggregate product, the following fire protection
facilities shall be provided:
a. First Aid Fire Fighting Equipment
b. CO2 extinguishers for electrical fire
c. Dry Chemical Extinguisher
d. Fire Siren

9.2.2 DESIGN CRITERIA FOR FIRE PROTECTION SYSTEM FOR AFSs WITH MORE THAN 1000 KL
ABOVE GROUND STORAGE CAPACITY:

a) Facilities shall be designed on the basis that city fire water supply is not available close to the
installation.

b) The fire water pumps shall be provided with auto start facility with pressure drop in fire water
network.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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c) The fire water system shall be based on single contingency for locations where total storage
capacity is up to 30,000 KL. Wherever water replenishment @ 50% or more is available, the
storage capacity can be reduced to 3 hours aggregate rated capacity of main pumps.

d) The fire water system shall be provided based on two largest fire contingencies simultaneously for
locations where total storage capacity is above 30,000 KL.

Wherever water replenishment @ 50% or more is available, single fire contingency shall be
considered for Fire water storage.

e) The hazardous areas shall be protected by a well laid combination of hydrants & monitors. AFS
having aggregate above ground storage capacity of less than & equal to 1000 KL are exempted

f) ATF above ground Petroleum storage tanks (fixed roof) of diameter larger than 30 m shall be
provided with fixed water spray system.

g) Fixed foam system or Semi-fixed foam system shall be provided on all tanks (fixed roof)
exceeding 18 m diameter storing ATF (Class B).

h) Existing AFS having above ground storage capacity more than 1000 KL, where inter distances in
a dyke and/or within dykes are not conforming to the provisions of this standard , proper
mitigation measures shall be taken to reduce the enhance risk involved, like the following:
(i) Arrangement of mutual aid scheme with the local airport operator/authority.
(ii) Arrangement with neighbouring agencies on sharing of firefighting facilities.
(iii) Clause 6.4.6 (f)

9.2.3 Tank Truck (TT) / Refuellers/ unloading facilities, Manifold area of product pump house and
Exchange pit shall be fully covered with alternate double hydrant and variable flow (pattern) water
cum foam monitors having multipurpose combination nozzles for jet, spray & fog arrangement
and located at a spacing of 30 M on both sides of facilities ensuring min foam application rate of
6.5 lpm/sq.m (in line with NFPA-11 for spill fire more than 1 inch deep) to the target zone of the
relevant facility.

i) The high volume long range ( HVLR) water cum foam monitors (variable type) to be
provided as under:

(i) AFSs with above ground storage capacity more than 1000 KL and meeting the safety distance
norms as per this standard, minimum one no. trolley mounted mobile type water cum foam HVLR
monitor shall be placed for covering the above ground tank farms storing Class B products based on
single largest tank diameter to be catered @ 8.1 lpm/m2.
(ii) For existing AFSs with above ground storage capacity more than 1000 KL and not meeting the
safety distance norms as per this standard, 2 nos. trolley mounted HVLR monitors shall be provided
for tank farms. Requirement of HVLR monitors shall be calculated for full surface fire scenario of the
largest tank @8.1 lpm/sq m. Refer clause 6.4.6 (f)
(iii) Provision for connecting / hooking the portable monitor shall be made in the hydrant system
around the fixed roof tanks at various strategic points.
(iv) Well laid procedures and plans shall be made and put into use for use of mobile HVLRs to combat
emergencies without loss of much time.
(v) The location of HVLRs to be planned in such a way that the very purpose of these monitors is
served and throw of the monitors is safely delivered at the aimed object. These high volume long
range monitors shall be located at a minimum distance of 15m subject to:
a. Monitors shall be positioned in such a way that throw of monitors are safely directed to the
target tank under full surface fire without damaging tank shell, tank pad and other objects.
b. The throw is directed on the inner upper surface of the tank and not in the middle of the tank
to prevent splash over.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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(vi) For determining the total foam solution requirement, potential foam loss from wind and other
factors shall be considered while designing.
(vii) Adequate foam drum/tank or reliable replenishment for foam induction system shall be provided
near the hook up points of mobile HVLRs with the hydrant system.

9.3 Fire Fighting at AFSs:

9.3.1 General:
I. Even though all efforts are made to avoid fires from taking place, it is necessary to have
firefighting equipment ready for use all times.
II. As stated earlier, to produce fire, three elements are necessary, namely, Fuel, Oxygen,
and Ignition. Elimination of any one of these three elements can stop a fire. All Firefighting
methods are based on this principle.
III. Fires are classified depending on the nature of fuel and the means of extinction as follows:

a. CLASS A: Fires involving solid materials such as wood, paper, cloth and natural fibres. Fire
extinguishers used for this type of fires use water for “Quench cooling”. This reduces the
temperature to below the ignition point of the fuel thereby inactivating the ignition and
stopping the fire.

b. CLASS B: Fires involving liquids or liquefiable solids such as petroleum products, methanol,
oils, fats etc. Extinguishers used for this type of fire are based on the principle of “Blanket
Smothering” and use foam, vaporising liquids, carbon-dioxide and dry powder. This cuts off
oxygen from the fuel and puts off the fire.

c. CLASS C: Fires involving gases or liquefied gases such as butane, methane, propane etc.
Extinguishers for this type of fire are based on “Smothering” and use foam, dry chemical
powder.

d. CLASS D: Fires involving metals such as magnesium and aluminium where extinguishers
work by smothering and use dry powders only.

e. CLASS E: Fires due to live electrical equipment. The supply to the live electrical equipment
involved in the fire must first be isolated before tackling the fire.

9.3.2 Fire Drills:

a) Location should carry out monthly mock fire drills to combat different fire situations that may occur
in the location. These Fire Drills should be conducted and recorded as per Monthly Fire Drill Report.
b) Six monthly mock fire drills (DCMP) shall be conducted involving the local neighbouring industries
and local statutory authorities. The outcomes of these drills shall act as learning tools for all the
personnel for effective fire-fighting.

Types of Fire extinguishers in use at AFS:

a) The most effective equipment to fight fires when they start is Fire Extinguishers. There are
different types of fire extinguishers in use at the AFSs given below:
Dry chemical powder (DCP) fire extinguisher: These are used in class B & C fires and fires
caused by electricity. It consists of a dry Chemical powder, usually sodium bicarbonate, and a
small cylinder of carbon dioxide under pressure, which acts as a propellant and discharges

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the powder in the form of a fog. The chemical reaction of the powder, when applied on the
fire, smothers the fire. The effective range of discharge is 8 to 12 feet.

b) Carbon dioxide type fire extinguisher: These are used on class B & class C fires and also on
electrical and electronic equipment. They consist of a liquid carbon dioxide under pressure
which, when discharged, reduces the oxygen content to a point where combustion cannot
continue.

c) All extinguishers and firefighting equipment shall be made clearly visible against a bright red
background, surrounded by bright yellow stripes. They should be located at easily accessible
places. All firefighting equipment shall be regularly maintained and inspected.

9.3.3 Portable Fire Extinguisher Specification:

i. All fire extinguishers shall conform to respective IS/UL or Equivalent codes, viz. 10/9 Kg DCP
Type (IS: 15683 /UL 299), 4.5/6, 8 Kg CO2 Type (IS: 2878/UL 154) & 25/50/75 Kg DCP Type
(IS: 10658/UL 299) and bear ISI/UL mark. BIS/UL or Equivalent certificates of all
extinguishers shall be maintained at the location.
ii) While selecting the Extinguisher, due consideration should be given to the factors like flow
rate, discharge time and throw in line with IS: 2190 / UL 711.
iii) The Dry Chemical Powder used in extinguisher and carbon dioxide gas used as expelling
agent shall be as per relevant IS/UL or Equivalent code.
iv) While selecting the dry chemical powder, due consideration should be given to the typical
properties viz. Apparent Density (0.65 +/-0.05), Fire Rating (144B), Thermal Gravimetric
Analysis (with decomposition at around 250oC) and foam compatibility.
v) Siliconised Potassium bicarbonate DCP powder (IS 4308:2003) / Mono-ammonium
phosphate based DCP powder (IS: 14609) can also be used for recharging DCP fire
extinguishers.
vi) Spare CO2 cartridges and DCP refills as required based on their shelf life should be
maintained. However, minimum 10% of the total charge in the extinguishers should be
maintained at the location.
vii) Portable fire extinguishers shall be located at convenient locations and are readily accessible
and clearly visible at all times. The no. of extinguishers at various locations shall be provided
as per OISD STD-117.
viii) The sand buckets shall have round bottom with bottom handle having 9 liter water capacity
conforming to IS: 2546. The sand stored in bucket shall be fine and free from oil, water or
rubbish.
ix) Rain protection of suitable design should be provided for all extinguishers & sand buckets.
x) The maximum running distance to locate an extinguisher shall not exceed 15 m.
xi) The extinguisher shall be installed in such a way that its top surface is not more than 1.5m
above the floor/ground level.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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The no. of extinguishers at various locations shall be provided as under:

Sr. No. Type of Area Scale of Portable Fire Extinguishers
2
1 Lube Godown 1no. 10Kg DCP extinguisher for every 200m or min.
2nos. in each Godown, whichever is higher.

2
2 Storage of Class A/B in packed 1no.10Kg DCP extinguisher for every 100m or min
Containers and stored in open/closed area 2Nos. in each shed, whichever is higher.
(Example- Downgraded ATF in drums or HSD
in drums for own use)

3 Pump House (Class A/B) UPTO 50HP 1No.10Kg DCP for 2 pumps.
Above 50 HP but below 100HP 1No.10Kg DCP for each pump.
Beyond 100HP 2nos. of 10Kg or 1no. 25Kg DCP for each Pump.

4 Tank Truck loading & Unloading 1No.10KgDCP extinguisher for each bay plus 1no
Gantry for Class A/B products .75Kg DCP extinguisher for each Gantry.
5 Aboveground Tank Farm 2nos. 10Kg DCP extinguisher for each tank plus
4nos. 25kg DCP extinguishers for each Tank Farm
positioned at four corners. In case of adjoining tank
farms, the no. of 25Kg extinguishers may be reduced
by 2nos. Per tank farm.
6 U/G & semi-buried Tank Farm 2nos. 10Kg DCP extinguisher for each Tank Farm
7 Other Pump Houses (fire pump house or water 1no. 10Kg DCP extinguisher for every two pumps or
pumps) min 2nos. 10Kg DCP extinguisher for each pump
House whichever is higher.
2
8 Admn. Building/ Store House 1no. 10Kg DCP extinguisher for every 200m or min.
2nos. 10Kg DCP extinguishers for each floor of
building/store whichever is higher.
9 DG Room 2nos. each 10Kg DCP & 4.5Kg CO 2 extinguishers
for each DG Room.
2
10 Main Switch Room/PMCC/Sub-station 1no. 4.5Kg CO2 extinguisher for every 25m plus 1
no. 9 litre sand bucket.
12 SCADA/Server/Computer room/Cabin 2nos. of 2Kg CO 2 or 2nos. of 2.5 Kg clean agent
extinguisher per computer room and 1 No. 2Kg CO 2 or
1No.1.0 Kg clean agent extinguisher per cabin.
13 Security Cabin 1no.10Kg DCP extinguisher per cabin
14 Canteen 1no.10Kg DCP extinguisher for 100m2
15 Workshop 1No.10Kg DCP extinguisher & 1no. 4.5Kg CO 2
extinguisher
16 Laboratory 1no.10Kg DCP extinguisher and 1no.4.5Kg CO 2
extinguisher.
2
17 Oil Sample storage Room 1no.10Kg DCP extinguisher per 100m or min.1no.
10Kg extinguisher per room whichever is higher.
18 Transformer 1no.10Kg DCP extinguisher per transformer
19 UPS/Charger Room 1no. 2kg CO 2 extinguisher.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Wheeled Fire Fighting Equipment

For AFSs having tanks of diameter larger than 9 m, following firefighting equipment shall be provided:-

Size of AFS (In KL) Water/Foam Monitor (Nos.)

having aggregate NIL
capacity of 1000 KL
having aggregate Minimum 2 Number of of suitable
capacity up to 10,000 KL capacity
having aggregate More than 2 Numbers of suitable
capacity more than 10,000 KL capacity

Foam compound trolley 200/210 liters shall be provided as under:-

Tank diameter (In m) Water/Foam Monitor (Nos.)

Up to 24 m 1 no.
24 m - 30 m 2 nos.
Above 30 m 3 nos.

Other Safety and PPE Gadgets required for the locations

Minimum fire accessories to be provided in a location without fire hydrant system areas follows:
Sand drum with scoop :4 Nos.
Safety helmet :1 No. per person.
Stretcher with blanket :2 Nos.
First Aid box :1 No.
Rubber hand gloves :2 Pairs.
Explosimeter :1 No.
Fire proximity suit :1 Suit.
Resuscitator :1 No.
Electrical siren (3Km range) :1 No.
Hand operated siren :One
Waterjel blanket :1 No.
Red & Green flag-fire drill :2 Nos. in each colour.
Self-Carrying Breathing Apparatus Set (30minutecapacity): 1 set with spare cylinder.

10. COMBINED AFS WITH LPG/POL FACILITIES/RETAIL OUTLETS IN THE SAME PREMISES:

The common water storage facility for fire-fighting purpose may be shared between AFS, POL
terminal/depot under following conditions:

a) AFS located within POL/LPG/RETAIL OULETS facility shall meet the design, layout & fire protection
system requirements of combined facilities corresponding to the stringent OISD standards and have
common boundary wall and ownership of both the facilities under same company. A separate PESO
license for such AFS located in a Retail Oulter/LPG Plant to be obtained. Existing license to be
amended for such AFS co-located inside a POL terminal/depot.The fire water requirement shall be
based on two fire contingencies simultaneously in the combined facility for above ground tanks at
such AFS having aggregated storage capacity more than 1000 KL and fire water storage capacity
shall be fixed accordingly. Where the AFS’s above ground storage capacity is less than 1000 KL,
single fire contingency shall be considered in determining the fire water requirement. The
responsibility of maintenance of these tanks and maintaining the water level in the storage tank at all
the time shall rest with occupier of POL/LPG/Retail Outlet with whom AFS will be located facility.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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b) For AFSs located adjacent to an existing LPG bottling plant, POL terminal/depot or retail outlet,
separate license to be obtained for such AFS. Requirement of fire-fighting facilities, safety distances
shall be guided as per details given in this standard. The common water storage facility for
firefighting purpose may be shared between AFS and LPG bottling plant.

c) The fire pump house may be common / separate. In case common pump house is provided the
control of the pump house shall remain with POL/LPG group.

11. FIRE WATER SYSTEM DESIGN (applicable for AFSs with aggregate capacity of more than
1000 KL in above ground tanks):

Water is used for fire extinguishments, fire control, and exposure protection of equipment, foam
application and personnel from heat radiation.
2
Header Pressure: Fire water system shall be designed for a minimum residual pressure of 7 kg/cm
at hydraulically remotest point in the AFS considering the design flow rate. The fire water
requirement shall be calculated as per OISD-117.

a) A fire water ring main shall be provided all around perimeter of the location facilities with
hydrants/monitors spaced at intervals not exceeding 30 M when measured aerially. Fire hydrants
and monitors shall not be installed within 15 Meters from the facilities/ equipment to be protected.

b) The AFS shall have facilities for receiving and diverting all the water coming to the installation to fire
water storage tanks in case of an emergency.

11.1 FIRE WATER DESIGN FLOW RATE

The fire water system shall be provided based on single largest fire contingency for all locations
where total tankage in the AFS with total above ground tankage more than 1000 KL up to 30,000
KL. The fire water system shall be provided based on two largest fire contingencies
simultaneously for all locations where total tankage in the AFS is more than 30,000 KL.

a) Fire water flow rate for a tank farm shall be aggregate of the following :-

i. For water flow calculations, all tanks farms having class B petroleum storage (above ground)
more than 1000 KL capacity, shall be considered irrespective of diameter of tanks and
whether fixed water spray system is provided or not.
ii. Water flow calculated for cooling a tank on fire at a rate of 3 lpm/sqm of tank shell area.
iii. Water flow calculated for exposure protection for all other tanks falling within a radius of (R
+30) m from centre of the tank on fire (R-Radius of tank on fire) and situated in the same dyke
at a rate of 3 lpm/m² of tank shell area.
iv. Water flow calculated for exposure protection for all other tanks falling outside a radius of
(R+30) m from centre of the tank on fire and situated in the same dyke at a rate of 1 lpm/m2
of tank shell area.
v. Water flow required for applying foam on a single largest tank by way of fixed foam system,
where provided, or by use of water/foam monitors whichever is higher.
vi. Foam solution applicable rate for cone roof tanks shall be taken as 5 lpm/sqm.
vii. Various combinations shall be considered in the tank farm for arriving at different fire water
flow rate and the largest rate to be considered for design.
Design flow rate shall be based on the combination of the above.

b) Supplementary water: Fire water flow rate for supplementary streams shall be based on using 4
single hydrant outlets simultaneously. Capacity of each hydrant outlet as 36 kl/hr shall be
considered at a pressure of 7 kg/cm2

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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The supplementary water stream requirement shall be in addition to the design flow rates.

11.2 FIRE WATER STORAGE:

a) The total water storage requirement shall be calculated in line with the recommendations of OISD
117.
b) Water for the firefighting shall be stored in easily accessible surface or underground or above
ground tanks of steel, concrete or masonry.
c) The effective capacity of the reservoir/tank above the level of suction point shall be minimum 4
hours aggregate rated capacity of pumps.
d) Fresh water should be used for firefighting purposes. In case sea water or treated effluent water is
used for firefighting purposes, the material of the pipe selected shall be suitable for the service.
e) Storage reservoir (RCC) shall be in two equal interconnected compartments to facilitate cleaning
and repairs. In case of steel tanks there shall be minimum two tanks and all the tanks shall be of
equal height/depth to prevent any migration/overflow due to difference in height/depth. During
maintenance of water tanks, availability of at least 50% of the water capacity shall be ensured.
f) Large natural reservoirs having water capacity exceeding 10 times the aggregate fire water
requirement can be left unlined.
g) In case existing land area is insufficient to have additional water tanks as per requirement, water
replenishment rate from the local airport operator/AAI may be added to existing water storage
capacity to fulfil the net requirement.

11.3 FIRE WATER PUMPS:

a) Fire water pumps having flooded suction shall be installed to meet the design fire water flow rate
and head. If fire water is stored in underground tanks, an overhead water tank of sufficient
capacity shall be provided for flooded suction and accounting for leakages in the network, if any.
Pumps shall be provided with suitable sized strainers on suction and NRVs on discharge lines.
b) The pumps shall be capable of discharging 150% of its rated discharge at a minimum of 65% of
the rated head. The Shut-off head shall not exceed 120% of rated head for horizontal centrifugal
pumps and 140% for vertical turbine pump.
c) At least one standby fire water pump shall be provided up to 2 nos. of main pumps. For main
pumps 3 nos. and above, minimum 2 nos. standby pumps of the same type, capacity & head as
the main pumps shall be provided. Fire water pumps shall be of equal capacity and head.
d) The fire water pump(s) including the standby pump(s) shall be of diesel engine driven type.
Where electric supply is reliable, 50% of the pumps can be electric driven. The diesel engines
shall be quick starting type with the help of push buttons located on or near the pumps or located
at a remote location. Each engine shall have an independent fuel tank adequately sized for 6
hours continuous running of the pump. Fuel tank should be installed outside of fire pump house. If
tanks are located inside the pump house, the vent shall have provision for venting outside the
pump house.
e) Fire water pumps & storage shall be located far away from the potential leak sources / tankage
are and shall be at least 30 M (minimum) away from equipment or where hydrocarbons are
handled or stored.
f) Fire water pumps shall be exclusively used for firefighting purpose only.
g) Suction and discharge valves of fire water pumps shall be kept full open all the times.
h) Jockey pump shall be provided for keeping the hydrant system /line pressurized at all times. The
capacity of the pump shall be sufficient to maintain system pressure in the event of leakages from
valves etc. Capacity of the jockey pump shall be 3% min. and 5 % max of the designed fire water
flow rate. Besides the main jockey pump, the stand by pump of same capacity and type shall be
provided.
i) Auto cut-in / cut-off facility should be provided for jockey pumps to maintain the line pressure.
j) The fire water pumps shall be provided with auto start facility which shall function with pressure
drop in hydrant line and specified logic even if initial pump does not start or having started, fails to

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from the use of OISD Standards/Guidelines.”
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build up the required pressure in the fire water ring main system the next pump shall start and so
on.

11.4 FIRE HYDRANT NETWORK:

a) Looping: The fire water network shall be laid in closed loops as far as possible to ensure multi-
directional flow in the system. Isolation valves shall be provided in the network to enable isolation
of any section of the network without affecting the flow in the rest. The isolation valves shall be
located normally near the loop junctions. Additional valves shall be provided in the segments
where the length of the segment exceeds 300 M.
b) Fire hydrant ring main shall be laid above ground ensuring that:
i) Pipe line shall be laid at a height of 300 mm to 400mm above finished ground level.
ii) The pipe support shall have only point contact. The mains shall be supported at regular
intervals:
a. For pipeline size less than 150 mm, support interval shall not exceed 3 mtrs.
b. Pipe line size 150mm and above support interval shall not exceed 6 meters or design
approved.
iii) The system for above ground portion shall be analysed for flexibility against thermal
expansion and necessary expansion loops where called for shall be provided.
(c) Fire hydrant ring main may be laid underground at the following places:
i) At road crossings.
ii) Places where above ground piping is likely to cause obstruction to operation and vehicle
movement.
iii) Places where above ground piping is likely to get damaged mechanically.
iv) Where Frost conditions warrant and ambient temperature is likely to fall below zero deg.
Centigrade underground piping at least 1 meter below the ground level should be provided.
Alternatively, in such cases for above ground pipelines, water circulation to be carried out.
(d) Fire water ring main laid underground shall ensure the followings:
i) Pipes made of composite material shall be laid underground
ii) The Ring main shall have at least one meter earth cushion in open ground, 1.5 m cushion
under the road crossings and in case of crane movement area pipeline shall be protected with
concrete/steel encasement as per design requirement and in case of rail crossing, provisions
stipulated by Indian Railways shall be complied.
iii) The Ring main shall be suitably protected against soil corrosion by suitable coating/wrapping
with or without cathodic protection.
iv) In case of poor soil conditions it may be necessary to provide concrete/ masonry supports
under the pipe line.
a. Size of hydrant pipeline
i) The hydraulic analysis of network shall be done at the design time. Also whenever fire
water demand increases due to addition of facilities or extensive extension of network,
fresh hydraulic analysis shall be carried out.
ii) The velocity of water shall not exceed 5 meter per second in fire water ring main.
iii) Fire water ring main shall be sized for 120% of the design water flow rate. Design flow
rates shall be distributed at nodal points to give the most realistic way of water
requirements in an emergency. It may be necessary to assume several combinations of
flow requirement for design of network.
iv) The stand post for hydrants and monitors shall be sized to meet the respective design
water flow rates.

b. GENERAL

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
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i) Fire water mains shall not pass through buildings or dyke areas. In case of underground
mains the isolation valves shall be located in RCC/brick masonry chamber of suitable
size to facilitate operation during emergency & maintenance.
ii) Associated Sprinkler/foam riser/branch connections meant for storage tanks if applicable
shall be taken directly to the outside of tank dyke and shall not pass through fire wall of
any adjacent tanks.
iii) The riser connections shall be taken directly from the mains and provided with separate
isolation valve outside of dyke.
iv) Suitable strainer shall be provided on sprinkler branch connection and shall be located
outside of dyke.

11.4.1 HYDRANT/MONITORS:

a) Hydrants/ monitors shall be located considering various fire scenario at different sections of
the premises to be protected and to give most effective service.
b) At least one hydrant post shall be provided at every 30 mtrs of external wall measurement or
perimeter of battery limit in case of high hazard areas. For non-hazardous area, they shall be
spaced at 45 mtrs. intervals. The horizontal range & coverage of hydrants with hose
connections shall not be considered beyond 45 mtrs.
c) Hydrants shall be located at a minimum distance of 15 mtrs from the periphery of storage
tank or equipment under protection. In case of buildings this distance shall not be less than 2
mtrs. and not more than 15 mtrs. from the face of building.
d) Provision of hydrants within the building shall be provided in accordance with IS: 3844.
e) Hydrant/Monitors shall be located along road side berms for easy accessibility.
f) Fixed water/water cum foam monitors on the network shall be provided with independent
isolation valves and Double headed hydrants with two separate landing valves.
Hydrants/Monitors shall be located with branch connection.
g) Double headed hydrants and monitors on suitably sized stand post shall be used. All hydrant
outlets/monitor isolation valves shall be situated at workable height of 1.2 meter above
ground or hydrant/monitor operating platform level.
h) Monitors shall be located to direct water on the object as well as to provide water shield to
firemen approaching a fire. The requirement of monitors shall be established based on
hazards involved and layout considerations.
i) Hydrants and monitors shall not be installed inside the dyked areas. However, as an
additional requirement, oscillating monitors may be provided in inaccessible area within the
dyke with isolation valve outside the tank farm (In cases inter distances between tanks in a
dyke and/or within dykes are not meeting the requirements).
j) TT/Refuellers loading & unloading facilities shall be provided with alternate hydrant / water
cum foam monitor of suitable capacity and size to ensure adequate coverage and located at
a spacing of 30 M on both sides of the gantry.
k) The hydrants & monitors shall be located at a minimum distance of 15 M from the hazard
(e.g.TT loading/unloading facilities) to be protected.

11.4.2 MATERIAL SPECIFICATIONS

The materials used in fire water system shall be of approved type as indicated below:-

a) Pipes: Carbon Steel as per IS: 3589/IS: 1239/IS: 1978 or Composite Material or its equivalent for
fresh water service. In case saline, blackish or treated effluent water is used, the fire water ring
main of steel pipes, internally cement mortar lines or glass reinforced epoxy coated or pipes made
of material suitable for the quality of water able to withstand the temperature and pressure shall
be used. Alternately, pipes made of composite materials shall be used. The composite material to

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be used may be as per API 15LR/API 15HR / IS12709. In case composite pipes are used they
shall be used underground.
b) Isolation Valves: Gate valve or quick shut off type isolation valves made of Cast Steel having
open/close indication shall be used. Other materials such as cupro-nickel for saline/blackish water
can be used. The material of the valve shall be suitable for the service.
c) Hydrants post:
Stand post - Carbon Steel
Outlet valves - Gunmetal/ Aluminum/ Stainless/ Steel/Al-Zn Alloy
d) Monitors / High Velocity Long Range Water Cum Foam Monitors (HVLR):
Approved / listed by international certifying agencies like UL/FM/ VdS/ LPC or equivalent Indian
certifying agencies. .
The electrical or hydraulic remote control mechanism shall be in line with Hazardous Area
Classification.
e) Fire Hoses:
Reinforced Rubber Lined Hose as per IS 636 (Type A) /Non-percolating Synthetic Hose (Type
B)/UL or Equivalent Standard.
f) Painting:
a. Fire water mains, hydrant & monitor stand posts, risers of water spray system shall be painted
with “Fire Red” paint as per of IS: 5.
b. Hose boxes, water monitors and hydrant outlets shall be painted with “Luminous Yellow” paint
as per IS: 5.
c. Corrosion resistant paint shall be used in corrosion prone areas.

11.4.3 FIXED WATER SPRAY SYSTEM

a) Fixed water spray system is a fixed pipe system connected to a reliable source of water supply
and equipped with water spray nozzles for specific water discharge and distribution over the
surface of area to be protected. The piping system is connected to the hydrant system water
supply through an automatically or manually actuated valve which initiates the flow of water. In
case the system is manually actuated, the isolation valve shall be located outside the dyke for
ease of access & operation.
b) Spray nozzles shall be directed radially to the tank at a distance not exceeding 0.6 M from the
tank surface.
c) For Tank Truck/refuellers loading gantries specifically for those cases which have obstructions in
water throw, sprinklers should be provided.

11.4.4 FOAM SYSTEMS

Fire fighting foam is a homogeneous mass of tiny air or gas filled bubble of low specific Gravity, which
when applied in correct manner and in sufficient quantity, forms a compact fluid and stable blanket
which is capable of floating on the surface of flammable liquids and preventing atmospheric air from
reaching the liquid.
Foams are classified by producing action of generation and expansion. Foam concentrate to be used
shall conform to IS: 4989 2006/UL-162 or Equivalent Standard

FOAM COMPOUND
Foam compound e used for fighting liquid fires is mechanical foam:

A. MECHANICAL FOAM
It is produced by mechanically mixing a gas or air to a solution of foam compound (concentrate) in
water. Various types of foam concentrates are used for generating foam, depending on the
requirement and suitability. Each concentrate has its own advantage and limitations. The brief
description of foam concentrates is given below.

TYPES OF MECHANICAL FOAM

Mechanical foam compound is classified into 3 categories based on its expansion ratio.

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a) LOW EXPANSION FOAM

i. Foam expansion ratio should be 20 to 1. as typically produced by self-aspirating foam branch
pipes.
ii. The low expansion foam contains more water and has better resistant to fire. It is suitable for
hydrocarbon liquid fires and is widely used in oil refinery, oil platforms, petrochemical and
other chemical industries.

b) MEDIUM EXPANSION FOAM

Foam expansion ratio varies from 20:1 to 200:1 as typically produced by self-aspirating foam branch
pipes with nets. This foam has limited use in controlling hydrocarbon liquid fire because of it's
limitations w. r. t. poor cooling, poor resistant to hot surface/radiant heat, etc.

c) HIGH EXPANSION FOAM

Foam expansion ratio vary from 200:1 to 1500:1, . This foam also has very limited use in controlling
hydrocarbon liquid fire because of its limitations w. r. t. poor cooling, resistant to hot surface/radiant
heat, etc. It is used for protection of hydrocarbon gases stored under cryogenic conditions and for
warehouse protection.

TYPES OF LOW EXPANSION FOAM

i) PROTEIN FOAM

The foam concentrate is prepared from hydrolyzed protein either from animal or vegetable source.
The suitable stabilizer and preservatives are also added.
The concentrate forms a thick foam blanket and is suitable for hydrocarbon liquid fires, but not on
water miscible liquids. The effectiveness of foam is not very good on deep pools or low flash point
fuels which have had lengthy pre-burn time unless applied very gently to the surface.
The concentrate is available for induction rate of 3 to 6%. The shelf life of concentrate is 2 years.

ii) FLUORO PROTEIN FOAM

This is similar to protein base foam with fluro-chemical which makes it more effective than protein
base foam.
The concentrate forms a thick foam blanket and is suitable for hydrocarbon liquid fires, but not on
water miscible liquids. The foam is very effective on deep pools of low flash point fuels which have
had lengthy pre burn time.
The concentrate is available for induction rate of 3 to 6% and the shelf life is similar to that of protein
base foam.

iii) AQUEOUS FILM FORMING FOAM (AFFF)

The foam concentrate mainly consists of fluoro carbon surfactants, foaming agent and stabilizer. This
can be used with fresh water as well as with sea water.

It produces very fluid foam, which flows freely on liquid surface. The aqueous film produced
suppresses the liquid vapour quickly. The foam has quick fire knock down property and is suitable for
liquid hydrocarbon fires. As the foam has poor drainage rate, the effectiveness is limited on deep pool
fires of low flash point fuels which have lengthy pre burn time.
The concentrate is available for induction rate of 1 to 6% and the shelf life is more than 10 years. This
can also be used with non-aspirating type nozzles.

iv) MULTIPURPOSE AFFF/ ATC Foam (Alcohol Type concentrate)

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Multipurpose AFFF concentrate is synthetic, foaming liquid designed especially for fire protection of
water soluble solvents and water insoluble hydrocarbon liquids. This can be used either with fresh
water or sea water.

When applied it forms foam with a cohesive polymeric layer on liquid surface, which suppresses the
vapour and extinguishes the fire. The foam is also suitable for deep pool fires because of superior
drainage rate and more resistive to hot fuels/radiant heat.
The 3% induction rate is suitable for liquid hydrocarbon fires and 5% for water miscible solvents. The
shelf life of concentrate is not less than 10 years. This can also be used with non-aspirating type
nozzles.
To be stored for AFSs storing/handling PBM (Power Boost Methanol) required for preparation of
Water Methanol Mixture. The product is as per standard UL-162, Govt. of India specs IS: 4989 Part 4.
The foam is to be used for Methanol fire.

v) FILM FORMING FLOURO PROTEIN FOAM (FFFPF)

FFFPF combines the rapid fire knock down quality of conventional film forming AFFF with the high
level of post fire security and burn back resistance of flouro-protein foam. The concentrate can either
be used with fresh water or sea water. The foam is suitable for hydrocarbon liquid fires including deep
pool fires of low flash point fuels which have had lengthy pre burn time.
The concentrate is available for induction rate of 3 to 6% and the shelf life is 5 years. This can also be
used with non-aspirating type nozzles.

TYPES OF MEDIUM AND HIGH EXPANSION FOAM

Synthetic foam concentrate is used with suitable devices to produce medium and high expansion
foams. This can be used on hydrocarbon fuels with low boiling point. The foam is very light in weight
and gives poor cooling effect in comparison to low expansion foams. The foam is susceptible to easy
break down by hot fuel layers and radiant heat.
The induction rate in water should vary from 1.5 to 3%. Many of the low expansion foam concentrate
can also be used with suitable devices to produce medium / high expansion foam.

ADVANTAGES OF LOW EXPANSION FOAM:

For combating large hydrocarbon fires particularly in a contained area like storage tank, foam has
proved useful for its inherent blanketing ability, heat resistance and security against burn back.
Aqueous Film Forming Foam (AFFF) compound is technically superior and compatible with other
firefighting agents.

11.4.5 CONVEYING SYSTEMS OF FOAM

Efficient and effective foam delivery system is a vital tool for its usefulness in controlling the fire.
The process of adding or injecting the foam concentrate to water is called proportioning. The mixture
of water and foam compound (foam solution) is then mixed with air in a foam maker for onward
transmission to burning surface.
The system consists of an adequate water supply, supply of foam concentrate, suitable proportioning
equipment, a proper piping system, foam makers and discharge devices designed to adequately
distribute the foam over the hazard.

Conventional systems are of the open outlet type, in which foam discharges from all foam outlets at
the same time, covering the entire hazard within the confines of the system. There are three types of
systems:-
i. Fixed
ii. Semi-Fixed
iii. Mobile

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i) Fixed Foam System

Fixed foam conveying system comprises of fixed piping for water supply at adequate pressure,
foam concentrate tank, educator, suitable proportioning equipment for drawing foam concentrate
and making foam solution, fixed piping system for onward conveying to foam makers for making
foam, vapour seal box and foam pourer.

ii) Semi-Fixed Foam System

Semi-fixed foam system gets supply of foam solution through the mobile foam tender. A fixed
piping system connected to foam makers cum vapour seal box in case of cone roof tanks and
foam maker and foam pourers in the case of floating roof tanks conveys foam to the surface of
tank.

iii) Mobile System

Mobile system includes foam producing unit mounted on wheels which should be self-propelled or
Towed by a vehicle. These units supply foam through monitors/foam towers to the burning
surface.

11.4.6 FOAM PROTECTION.

A. FIXED ROOF TANK PROTECTION

B. PROTECTION FOR DYKE AREA / SPILL FIRE

STORAGE TANK PROTECTION:

A. FIXED ROOF TANK PROTECTION:

Foam conveying system shall have a vapour seal chamber before the foam discharge outlet.
Features of the foam system for fixed roof protection shall be as follows:
i) System shall be designed to create foam blanket on the burning surface in a reasonably short
period.
ii) Foam shall be applied to the burning hazard continuously at a rate high enough to overcome
the destructive effects of radiant heat.
iii) The vapour seal chamber shall be provided with an effective and durable seal, fragile under
low pressure, to prevent entrance of vapour into the foam conveying piping system.
iv) Where two or more pourers are required these shall be equally spaced at the periphery of the
tank and each discharge outlet shall be sized to deliver foam at approximately the same rate.
Tanks should be provided with foam discharge outlets/pourers as indicated below :-

Tank diameter and requirement of Foam Pourer

(In M) (Min. Nos.)
Above 18 &up to 20 2
Above 20 &up to 25 3
Above 25 &up to 30 4
Above 30 &up to 35 5
Above 35 &up to 40 6
Above 40 &up to 45 8
Above 45 &up to 50 10

In case foam pourers are provided on tanks having diameter up to 18 m, minimum 2 nos. foam
pourers shall be provided.
The estimation of number of foam discharge outlet is based on pourer capacity of 1000 lpm at a
pressure of 7 kg/sq.cm (g) upstream of educator. This can be suitably adjusted for different pourer
capacity in accordance with above. Testing of foam pourer system shall be done by reversing the inlet
so as to prevent ATF from entering the storage tank.

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B. PROTECTION FOR DYKE AREA / SPILL FIRE

Portable monitors/foam hose streams shall be provided for fighting fires in dyked area and spills.

For Class B above ground tanks more than 1000 KL aggregate capacity:
Two nos. portable foam generator for each AFS.

11.4.7 FOAM APPLICATION

A. APPLICATION RATE

The minimum delivery rate for primary protection based on the assumption that all the foam reaches
the area being protected shall be as indicated below :-
For cone roof tanks containing liquid hydrocarbons, the foam solution delivery rate shall be at least 5
lpm/ sqm of liquid surface area of the tank to be protected.
In determining total solution flow requirements, potential foam losses from wind and other factors shall
be considered.

B. DURATION OF FOAM DISCHARGE

The equipment shall be capable of providing primary protection at the specified delivery rates for the
following minimum duration.
i) Tanks (fixed roof) containing Class 'B' : 65 minutes.
ii) Where the system's primary purpose is for spill fire protection such as dyked area and non dyked
area (TT/refuellers etc) : 30 minutes.

C. WATER FOR FOAM MAKING

Water quantity required for making foam solution depends on the percent concentration of foam
Compound. Foams in normal use have a 3% to 6% proportioning ratio. However, foam supplier data
shall be used for determining water requirement.

D. FOAM QUANTITY REQUIREMENT

1. For locations aggregate capacity upto 30,000 kl (Single contingency):

i) Foam solution application at the rate of 5 lpm/ sqm for the liquid surface of the single largest cone
roof tank.

2. For locations aggregate capacity more than 30,000 kl (Double contingency). (Assume, two cone
roof tank farm are the two largest simultaneous fire risk in a double contingency Installation for the
purpose of foam requirement).

i) Foam solution application at the rate of 5 lpm/ sqm for the liquid surface of the single largest cone
roof tank.
ii) Two hose streams of foam each with a capacity of 1140 lpm of foam solution.

The aggregate quantity of foam solution should be largest of D1(i) & D2(i+ii) whichever is higher
in line with recommendations of OISD 117.

FOAM COMPOUND STORAGE

Foam compound should be stored as explained in IS-4989:2006/UL-162. Alcohol Resistant Foam

shall be used for handling methanol/ ethanol or furfural fires. Minimum 1000 litres of Alcohol Resistant
Foam compound shall be maintained at the AFSs handling methanol.

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Shelf life of foam compound shall be taken from manufacturer’s data. Foam compound shall be tested
periodically as per OEM guidelines to ensure its quality and the deteriorated quantity replaced. The
deteriorated foam compound can be used for fire training purposes.
Care shall be taken to avoid mixture of two/more different grades/batches of foam in a foam storage
tank. In such cases foam shall be tested on yearly basis to check its efficacy and record maintained.
For details of type of tests & their periodicity, refer IS 4989: 2006/UL-162 or Equivalent Standard.
Quantity of foam compound equal to 100% of requirement as calculated above should be stored in an
AFS.

11.4.8 SCADA/SERVER ROOM PROTECTION

SCADA/server room should be protected by Clean Agent Fire Extinguishing System.

Persons should be evacuated from the areas before the clean agent fire extinguishing system comes
into operation.
Each hazard area to be protected by the protection system independently. The time needed to obtain
the gas for replacement to restore the systems shall be considered as a governing factor in
determining the reserve supply needed. 100% standby containers shall be considered for each
protected hazard. Storage containers shall be located as near as possible to hazard area but shall not
be exposed to fire. Storage containers shall be carefully located so that they are not subjected to
mechanical, chemical or other damage. All the components of the system shall be capable of
withstanding heat of fire and severe weather conditions.

11.4.9 FIRST AID FIRE FIGHTING EQUIPMENT

Emergency Trolley and Emergency kit

A trolley containing Fire Proximity Suit, B. A. Set, Water Jel Blanket, Resuscitator, First Aid Box,
Stretcher with blanket, Spare fire hoses, Special purpose nozzles, Foam branch pipes, Explosive
meter, Emergency trolley shall be provided at AFSs with above ground storage tanks with aggregate
capacity of more than 1000 KL. An emergency kit shall be provided consisting of safety items and
shall be readily available at AFSs with above ground storage tanks with aggregate capacity of more
than 1000 KL. All the items of the kit shall be kept on a trolley specifically designed for the purpose.
For all other AFSs, Fire Proximity Suit, Water Jel Blanket, Resuscitator, First Aid Box, 2 nos. 10/9 kg
DCP fire extinguishers, Safety helmets, Fire buckets, etc shall be placed at an easily accessible
location inside the AFS:

11.5. Emergency shut Down (ESD)/Emergency Shutdown Button (ESB) logic for Automation
System

The ESD/ESB for automated locations shall be provided in SCADA room as well as at various
strategic locations including the tarmac. ESD/ESB system shall be only through push buttons with
wired connection.

i) Actuation / pressing of any ESD shall initiate following actions:

1. Shutdown of all operations.

2. Power Shutdown
3. Process Shutdown shall include the following:
-To stop all unloading and delivery pumps
-Barrier gates & access control system to open
-All MOVs to close.

ii) Power Shutdown shall initiate the following:

1. Trip all the panels other than Emergency panel. The Emergency panel should host Siren, Bore
wells, critical High Mast tower lights outside the licensed area, security cabin, critical lights in

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unloading/Refuellers loading area, Admin block, MCC room and power to the control
room/Automation system.

2. There should be interlock between ESD for operations shut down and ESD for Power shut down
so that full power shut down takes after a time lag required for closing the MOVs and full closure
of valves shall be ensured. The time lag shall be location specific.
At pipe line receipt locations alarm signal should be exchanged between the two control rooms so that
necessary actions are taken by the operating personnel at both ends.

iii) Inspection and Testing:

The system shall be checked during each fire drill conducted with full system shut down and records
shall be maintained.

11.6 FIRE SAFETY ORGANISATION/ TRAINING

a) ORGANISATION

A well- defined comprehensive Onsite Emergency Plan as per OISDGDN- 168 shall be drawn.

b) TRAINING

i) Training on safety, firefighting and rescue operation shall be compulsory for all officers, operators,
security, T/T drivers & contract workmen, clericals who are likely to be present/working in the
installation& record maintained. The above training shall be imparted before induction.
Each employee shall undergo a refresher course once in every three years after initial training.
ii) The training shall be conducted through an expert agency such as Fire Brigade/recognized
training institute/in-house experts/Oil industry approved reputed agency. The training also include
usage of personnel protective equipment.
iii) All operating personnel shall be given training on Live Fire training representing fire scenarios
likely to occur at AFS installations.
iv) Every employee or authorized person of contractor working in the AFS shall be familiarized with
fire siren codes and the location of fire siren operating switch nearest to his place of work.
v) Instructions on the action to be taken in the event of fire should be pasted at each siren point and
familiarity with these instructions ensured and recorded.
vi) Monthly fire drills considering various scenarios shall be conducted regularly with full involvement
of all employees of the AFS. The mock drill (ERD: Emergency Response Drill) shall include the
full shut down system activation once in six months for all AFSs. AFSs with Hydrant Refuelling
System should carry out DCMP with/without shutdown of HRS. However, periodic checking of
ESD shall be done at these AFSs.
vii) The offsite disaster mock drills shall be conducted periodically as per local statutory requirements.
The company should approach and coordinate with the district authority for conducting “Offsite
Mock Drills”.
viii) The post drill analysis should be carried out & discussed emphasizing areas of improvements.
ix) The record of such drills should be maintained at the location.
x) Mock drill scenarios shall include all probable scenarios and the key areas like tank Farm,
Loading/unloading Gantry, Pump House, etc., shall be covered at least once in six months.
xi) Security staff should be trained as first responders for firefighting and rescue operation along with
plant operating personnel through oil industry approved reputed institute.

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c) Mutual Aid:

Installation shall have a ‘Mutual Aid' arrangement with nearby industries to pool in their resources
during emergency.
Mutual Aid arrangement (valid for a maximum period of 2 years) shall be prepared and signed by all
Mutual Aid members. Fresh arrangement shall be made on expiry of 2 years or whenever there is
change in the signatories to the arrangement. Quarterly meeting of Mutual Aid members may be
conducted and the minutes to be recorded. The minutes shall be reviewed in the subsequent
meetings.
11.7 DISASTER CONTROL MANAGEMENT PLAN

i) Each AFS shall prepare a Comprehensive Disaster Control Management Plan covering all
emergency scenarios outlining the actions to be taken by each personnel in the event of all
emergencies including fire emergency for effective handling.
ii) Recommendations and its mitigation, based on HAZOP and QRA study shall be incorporated in
the DCMP.
iii) The key action points for fire emergency shall be displayed at strategic locations in the AFS.

11.8 FIRE PROTECTION SYSTEM, INSPECTION AND TESTING

i) The fire protection equipment shall be kept in good working condition all the time.
ii) The fire protection system shall be periodically tested for proper functioning and logged for record
and corrective actions.
iii) One officer shall be designated and made responsible for inspection, maintenance & testing of
fire protection system.
iv) The responsibilities of each officer shall be clearly defined, explained and communicated to all
concerned in writing for role clarity.
v) In addition to the following routine checks/maintenance, the requirements of OISD-STD-142 in
respect of periodic inspection, maintenance & testing of firefighting equipment shall be complied
with.

a) FIRE WATER PUMPS

i) Every pump shall be test run for at least half an hour or as per OEM guidelines, whichever is
higher twice a week at the rated head & flow.
ii) Each pump shall be checked, tested and its shut-off pressure observed once in a month.
iii) Each pump shall be checked & tested for its performance once in six months by opening required
nos. of hydrants/monitors depending on the capacity of the pump to verify that the discharge
pressure, flow & motor load are in conformity with the design parameters.
iv) Each pump shall be test run continuously for 4 hours at its rated head & flow using circulation line
of fire water storage tanks and observations logged once a year.
v) The testing of standby jockey pump, if provided, shall be checked weekly. Frequent starts & stops
of the pump indicate that there are water leaks in the system which should be attended to
promptly.

b) FIRE WATER RING MAINS

i) The ring main shall be checked for leaks once in a year by operating one or more pumps &
keeping the hydrant points closed to get the maximum pressure.
ii) The ring mains, hydrant, monitor & water spray header valves shall be visually inspected for any
missing accessories, defects, damage and corrosion every month and records maintained.

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iii) All valves on the ring mains, hydrants, monitors & water spray headers shall be checked for leaks,
smooth operation and lubricated once in a month.

c) FIRE WATER SPRAY SYSTEM

i) Water spray system shall be tested for performance i.e. its effectiveness & coverage once in six
months.
ii) Spray nozzles shall be inspected for proper orientation, corrosion and cleaned, if necessary at
least once a year.
iii) The strainers provided in the water spray system shall be cleaned once in a quarter and records
maintained.

d) FIXED/SEMI FIXED FOAM SYSTEM

Foam system on storage tanks should be tested once in six months. This shall include the testing
of foam maker/chamber. The foam maker/chamber should be designed suitably to facilitate
discharge of foam outside the cone roof tank. After testing the foam system, piping should be
flushed with water.

e) CLEAN AGENT SYSTEM

Clean agent fire extinguishing system should be checked as under:-
i) Agent quantity and pressure of refillable containers shall be checked once every six month.
ii) The complete system should be inspected for proper operation once every year.

f) HOSES

Fire hoses shall be hydraulically tested once in six months to a water pressure as specified in relevant
IS/UL/Equivalent codes.

g) COMMUNICATION SYSTEM

Electric and hand operated fire sirens should be tested for their maximum audible range once a week.

h) FIRE WATER TANK/RESERVOIR

i) Above ground fire water tanks should be inspected externally & internally as per OISD-STD-129.

ii) The water reservoir shall be emptied out & cleaned once in 3 years. However, floating leaves,
material or algae, if any shall be removed once in 6 months or as & when required.

i) FIRE EXTINGUISHERS

Inspection, testing frequency and procedure should be in line with OISD-STD- 142.

j) COMMON FIRE FIGHTING FACILITY FOR CLUSTER OF AFSs

Where there is cluster of AFSs of different companies, provision of jointly owned common firefighting
facility may be considered. The cluster of AFSs should be treated as single entity for the purpose of
designing firefighting facility, considering one of the following two categories as the case may be:

(a) Total tankage upto 30,000 Kl.

(b) Total tankage more than 30,000 Kl.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
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The common firefighting facility shall be located at a safe distance, beyond the blast overpressure
zone.

12 MAINTENANCE & INSPECTION OF EQUIPMENT

12.1 GENERAL :

This section covers the maintenance and inspection practices to be followed to ensure safe and
trouble free operation of various equipment.

12.2 MAINTENANCE SCHEDULES :

To facilitate the maintenance service to be rendered in a planned manner, a preventive maintenance

schedule covering the necessary work to be done, mentioning the periodicity i.e. daily, weekly,
monthly, half yearly and yearly schedules, must be worked out. Basic recommendations given by the
manufacturers should be considered and modified bearing in mind the local conditions.

12.3 PERSONAL PROTECTIVE EQUIPMENT:

Personnel protective equipment such as safety shoe, hand gloves, apron, safety goggles, safety belt,
helmet, ear muff, , bump caps, fluorescent jackets, self-contained breathing apparatus (SCBA),
resuscitator etc. as applicable shall be worn while carrying out maintenance. Such equipment shall be
checked periodically and maintained for ready use in normal and emergency situations.
For details refer OISD STD-155.

12.4 WORK PERMIT SYSTEM :

Working in hydrocarbon processing/handling installation presents special risk and in order to provide
safe working conditions and to carry out the work safely, a work permit system shall be followed. The
basic purpose of the work permit system is to ensure that work is carried out in the safest possible
manner to prevent injuries to personnel, protect property from damage, avoid fire etc. Any
maintenance, inspection, disassembly or removal of fittings shall not be carried out without a proper
work permit and approved procedure.

Cold Work: An activity which does not produce sufficient heat to ignite a flammable air-hydro carbon
mixture or a flammable substance.

Hot Work: An activity that can produce a spark or flame or other source of ignition having sufficient
energy to cause ignition, where the potential for flammable vapours, gases, or dust exists.

Based on the nature of work to be performed, the following minimum type of work permits shall be
used:-

1. Cold Work Permit

2. Hot Work Permit
3. Confined Space Entry
4. Electrical isolation and Energisation permit
5. Working at Heights.

All Maintenance/ Inspection jobs shall be carried out in line with OISD Standard; OISD-STD-105 on
"Work Permit System". Working at heights shall be as per provisions of OISD-GDN-192.

12.5 APPLICABLE STANDARDS :

1. Electrical maintenance / inspection, provisions of OISD-STD-137 shall be adhered to.
2. OISD STD -130 on Inspection of pipes, valves and fittings shall be followed.
3. OISD Standard No. OISD-119 on Selection, Operation and Maintenance of Pumps

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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4. "OISD Standard No. OISD-123 on "Inspection and Maintenance of Rotating Equipment

components

12.6 INSPECTION & MAINTENANCE OF VARIOUS FACILITIES IN AFS :

EQUIPMENT:

A. STORAGE TANKS:

OISD Standard OISD-STD-129 on "Inspection of storage tanks shall be followed.

Petroleum products and water are stored in tanks in AFSs. Storage tanks of various types and sizes
are used. The failure of any part of a tank is not desirable.

Timely inspection and preventive maintenance of these storage tanks assume high importance.
Accordingly, the inspection schedules of storage tanks are to be prepared and implemented.
This standard covers the minimum inspection requirements for atmospheric and low-pressure storage
tanks constructed as per standards IS-803, API-STD- 650, IS 10987 or equivalent. The various types
of storage tank inspections along with types of repairs and areas of inspections have been covered in
this standard.

B. PIPES, VALVES AND FITTINGS.

Safety in AFSs comes through continuous efforts at all stages and as such it can be ensured by
observing that plant and equipment are designed, constructed, tested and maintained as per
Engineering Standards and subsequent modifications and repairs are conforming to the same
standard.

This standard covers minimum inspection requirements for plant piping and off-site piping constructed
as per Standard ANSI B-31.4 or equivalent. Areas to be inspected, facilities needed for inspection,
frequency of inspection, likely causes of deterioration of pipelines in service and inspection of pipe
fittings and repairs have been specified. Also included briefly are the inspection and testing
requirements for the new pipelines during fabrication and prior to commissioning.

Type of Inspection

a. External inspection

Includes Visual inspection & Ultrasonic thickness survey

1. Visual Inspection :

Shall covers all the 10 parameters as given in OISD-130, Clause 8.1.1, (viz. Leaks, Misalignment,
Supports, Vibration, External Corrosion, Bulging, Bowing & Sagging, Mechanical Damage, Paint /
coating failure, Cracks, particularly near weld joints and Insulation damage

2. Ultrasonic Thickness Testing

Shall be carried out to ascertain the remaining wall thickness of piping. Minimum readings to be taken
are to be guided by OISD-130, Clause 8.1.2.

3. Radiographic Inspection:

Critical spots which cannot be inspected by Ultrasonic testing (UT) shall be radiographed in line with
OISD-130, Clause 8.1.3.

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b. Comprehensive testing

I. Shall include all parameters as per External Inspections mentioned above.

II. In addition, following one or, more of the tests given hereunder shall also be carried out.

1. Other NDT Tests

Like Dye Penetration Test, Magnetic Particle Test, Hammer Tests.

These shall be conducted only if necessitated after external checks and thru’ a competent
agency.

2. Pressure test

Pressure test for all pipelines in operation should be carried out with ATF at as per the code to which
the same is designed.
.
C).FLANGES, GASKETS AND BOLTS:

All valves shall be inspected and tested to ensure conformation to required specifications and for leak
tightness. The closure torque during testing for hand wheel and gear operated valves shall not be
greater than that obtainable by hand tightening.

D) HOSE AND FLEXIBLE CONNECTION:

Loading unloading hoses shall be inspected & tested at maximum interval of 6 months as detailed in
OISD-STD-135 on "Inspection of Loading and Unloading Hoses for petroleum products" and records
maintained thereof.

E) STRAINERS AND FILTERS:

Strainers & filters shall be inspected and cleaned as per following frequency, unless it warrants earlier
inspection:

TYPE / LOCATION FREQUENCY

Upstream of Pump Suction Quarterly
Upstream of PD meter Quarterly
Sprinkler strainer: Quarterly

F) SAFETY RELIEF VALVES

Safety Relief valves shall be tested once in a year. Further an on-stream visual inspection should be
carried out at least once in every 6 months to check the following:

i. Blinds do not exist.

ii. Upstream and downstream isolation valves, if any, are opened and sealed.
iii. Seals protecting the spring setting have not been broken.
iv. Relief device is not leaking. This shall be checked visually or by hand touch at outlet nozzle
wherever practicable.

G. ROTARY EQUIPMENT:
i) PUMPS :

Periodic checks as detailed in Annexure-(3) to be followed.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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ii) DIESEL ENGINES:

For maintenance of Diesel Engines Original Equipment manufacturer guidelines and OISD-STD-
127 shall be followed.

iii) PRESSURE GAUGES

Pressure gauges shall be checked daily for its proper functioning and shall be calibrated once in 6
months.

iv) QUANTITY MEASURING DEVICES

Calibration of the flowmeters shall be carried out in line with requirement of Department of Legal
Metrology.

H. FIRE FIGHTING EQUIPMENT

Firefighting equipment shall be inspected and tested as per OISD-STD-142 and record
maintained.

I. ELECTRICAL EQUIPMENT

Proper functioning of electrical equipment can only be ensured by means of periodic preventive and
predictive maintenance of the equipment. This enhances equipment life and also ensures safety of
the equipment, installation and operating personnel.

Maintenance shall be daily, weekly, quarterly or annual depending upon the type of equipment.
Adequate logs shall be maintained to ensure that maintenance is carried out as per approved
checklists. Preventive maintenance shall be carried out as per schedules laid down in OISD-STD-
137.

Special emphasis shall be laid on the maintenance of equipment installed in hazardous areas.

All electric apparatus and wiring in a hazardous area shall at all times be so maintained as to retain
the characteristic on which their approval has been granted.

Precautions to be taken for repairs and testing of flameproof equipment shall be as below:

i. No Flame proof or intrinsically safe apparatus shall be opened and no work likely to impair the
safety characteristics of such apparatus or electric wiring connected thereto shall be carried out
until all voltage has been cut off from said apparatus or wiring. The voltage shall not be restored
thereto until the work has been completed and the safety characteristics provided in connection with
the apparatus and wiring has been fully restored.

ii. Use of soldering apparatus or other means involving flame, fire or heat or use of industrial type
of apparatus in a zone “1” area shall be permitted for the purposes of effecting repairs and testing
and alterations, provided that the area in which such apparatus or wiring has been installed, has
first been made safe and certified by a competent person after testing with an approved gas –
testing apparatus to be safe and free from inflammable vapours, gases or liquids and is maintained
in such conditions, so long as the work is in progress.

iii. No alteration that might invalidate the certificate or other document relating to the safety of the
apparatus shall be made to any apparatus.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Replacement fasteners, nuts, studs and bolts shall be of the type specified by the manufacturer for
the particular apparatus. No attempt shall be made to replace or repair a glass in a flameproof
enclosure e.g. in a luminaire or other enclosures, except by replacement with the complete
assembly or part obtainable from the manufacturer, complying with the approval certificate.

If replacement components such as cable glands, conduit or conduit accessories, are available only
with thread forms which differ from those provided on the apparatus, suitable adaptors having
necessary certification and approval shall be employed.

iv) Equipment enclosures and fittings shall be examined to see that all stopping plugs and bolts are
in position and properly tightened. Locking and sealing devices shall be checked to ensure that
they are secured in prescribed manner.

v) If at any time, there is a change in the area classification or in the characteristics of the
flammable material handled in the area or if the equipment is relocated in the area, the area
classification drawing should be correspondingly revised and a check shall be made to ensure
that the equipment selection corresponds to the revised area classification.

vi) A system shall be established to record the results of all inspections and the action taken to
correct defects.

13 MAMANGEMENT OF CHANGE (MOC)

13.1 Objective
Institute a system whereby any intended changes in facilities, documentation, personnel,
defined operating procedures & working environment including new processes are thoroughly
evaluated, and managed to ensure that health, safety and environmental risks arising from
these changes are effectively controlled.

13.2 Scope & Applicability

Applicable to all Aviation Fuel Stations. All temporary, permanent & emergency changes are
covered by this procedure.

13.3 Guiding Standard

OISD-GDN-178 Guidelines on Management of Change

13.4 Types of Changes

i. Changes in Facilities and software
a. Addition, alteration or removal of an equipment / instrument or, a part thereof.
b. Modification in piping system including valves
c. Changes in product / material specifications
d. Changes in software in computerised environment

ii. Changes in Operating Procedures

a. Deviations from the manualised operating procedures / approved SOPs.

iii. Changes in Personnel

a. Changes in operating personnel (newly recruited / re-assigned officers and
workmen).

13.5 Nature of Changes

i. Permanent Change

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Long term & durable change. Not categorised as a Temporary Change.

ii. Temporary Change

Any change which has a defined lifetime and which will be removed before a defined
date. (Usually not more than 6 months).

iii. Emergency Change

Any change which is to be implemented to address an immediate occupational health,
safety, environmental or, product quality situations.

13.6 Procedure for Management of Change (MOC)

Various steps involved in the MOC process are as follows:

a. Identification of possible improvements to existing processes

b. Initiation of Change Request with justification
c. Scrutiny & Approval Procedure
d. Execution of Change
e. Commissioning, training & updation of documents

A. Identification of required change

In order to improve efficiency, operability & safety, changes may be contemplated. But
proposed changes shall be thoroughly evaluated by satisfying the following queries :
i. Is the change necessary?
ii. Is it economical?
iii. Is there a better alternative?

B. Initiating Change Request

The format (Annexure-4) shall be initiated with the following information:
i. Description of proposed change, including object of change (facilities / procedure/ new
manpower etc.)
ii. Technical reason for the proposed change
iii. Potential impact of the change on health, safety, work environment & product quality
iv. Compliance to guiding Standards & Regulatory requirements
v. Nature of the change: temporary / permanent, normal / emergency etc.
vi. Proposed documents incorporating the changes: revised P&ID (for facilities change)
or, revised SOP (for changes in procedures) with revised PFD (Process Flow
Diagram), & P&ID if required.
vii. For introduction of new personnel, details of training imparted to the personnel on the
changed facility / process and the related health, safety & emergency response issues.

C. Scrutiny & Approval Procedure

The MOC Request will be reviewed & approved / rejected by the appropriate competent
authorities as given in the DOA table in Annexure-5. Any change in the existing process or,
new processes are required to be discussed and suggestions / acceptance of the Committee
are to be recorded in the MOC application. Competent authorities shall ensure that the
proposed changes in design / process are completely safe thru’ appropriate checks /
evaluations, which may include PHA (Process Hazard Analysis) and HAZOP (Hazard &
Operability study).

D. Execution of Change
On approval of the MOC Request, modifications / changes in facilities/ procedures can be
executed / effected. Physical inspection of the changes done in line with the MOC approval

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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shall be conducted by appropriate official as per DOA in Annexure-5 and confirmed thru’ a
signed document.

E. Commissioning, Training & Updation of documents

On completion of the modifications & inspection as stated above, facilities can be
commissioned for regular operations, after ensuring that the concerned officers, operators
including contract workmen & security personnel - wherever applicable are adequately
informed & suitably trained on the impact of these changes.
As built records with the approved MOC, revised P&ID and layout drawings shall be
maintained properly.

14 EMERGENCY PREPAREDNESS PLAN AND RESPONSE

14.1 General

Several major accidents leading to grave disasters have occurred across the world in the past. The
lessons learnt from the disasters made it essential to draw a Disaster Control Management Plan to
handle such eventuality. Disaster Control Management Plan is essential to obviate such an
eventuality by providing the measures to contain the incident and minimise the after affects.

The best way to manage any emergency is to prevent it. Following guidelines for emergency
prevention shall be followed:
i. Sound engineering practice in the design, fabrication, installation and maintenance of
facilities.
ii. Careful selection and correct use of equipment.
iii. Observance of safety and security regulations.
iv. Deployment of eligible/qualified manpower.
v. Development and adherence to site specific operating procedure (SOP).
vi. Proper and constant training and guidance to all personnel working in the installation with
particular reference to product knowledge and maintenance practices.
vii. Following Management of change (MOC) procedure.
viii. Good House-keeping.
ix. Constant supervision and alertness.

14.2 Statutory and other Requirements

The relevant provisions of the concerned Acts and Rules as indicated in para 4.0 shall apply.

Further guidelines have been provided in Petroleum and Natural Gas Regulatory Board (Codes of
Practices for Emergency Response and Disaster Management Plan (ERDMP)) Regulations, 2010,
published by Petroleum & Natural Regulatory Board shall be referred for further details.

A detailed guideline on the subject is also provided in OISD-GDN-168, which may be referred for
guidance.

15 TRAINING

15.1 General

Products handled at the AFS are hazardous in nature. Therefore, safety education and training
requires great attention. Training courses including the refresher courses shall be conducted to
develop the skills and safety awareness of employees, contractor workers, security staff and crew
members.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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15.2 Designated safety officer

A dedicated, qualified and experienced officer should be designated as ‘Safety Officer’ of the AFS
after training. He should be given exposure to Hazop, Risk Assessment, Safety Audit and upkeep of
fire fighting facilities and conducting Safety Meetings.

Duties and responsibilities of the dedicated/designated safety officer shall be to build & ensure a safe
working environment at the location, and also to advise & assist the location in-charge in complying
statutory requirements or otherwise concerning health, safety, security & environment of the location.
These duties shall include the following:

a) Advise various functions within the location in planning and organizing measures necessary for safe
& secure work environment, including effective prevention and control of personal injuries.
b) Conduct routine safety checks on AFS facilities & equipment to ensure conformity with prevalent
norms/guidelines.
c) Updation and implementation of fire organization chart, Disaster Control Management Plan, Risk
Assessment & other statutory plans.
d) Co-ordinate and conduct regular mock drill, ERD, Mutual aid meeting with neighbouring
industries/OMCs
e) Conduct safety meeting and monitor compliance with statutory and OISD norms.
f) Implementation of sound safety culture to promote safe practices including wearing of personnel
Protective Equipment (PPEs) amongst all section of personnel at the location-employees, contract
labour, TT crew, Security staff and Visitors.
g) Conduct safety audit and co-ordinate/facilitate for conducting other internal and external audits.
h) Prepare & Monitor periodical compliance status of various audit recommendations.
i) Prepare & submit to appropriate authorities various periodical reports on safety, security, health,
environment including training. Maintain all related records for the purpose of reference & audits.
j) Monitor the appropriate administration of security measures (gate passes,, antecedent verification,
access control procedures).
k) Ensure and monitor implementation of effective work permit system and record maintained.
l) Near miss analysis with specific focus on the root causes, reporting, dissemination of finding with all
concerned across the location and corrective action required for preventive measures.

15.3 Specific required training for employees:

All operating personnel including the contract workmen, security, TT crew, shall be given training,
including refresher courses as per OISD STD 154.
However, following specific trainings are also to be imparted to the AFS personnel.
Training should be based on the needs of the job.
Training on live fire simulation in an area designated for this purpose.
Training through Fire Department.
Training on first aid by recognised agencies.
For supervisors, intimate knowledge of the operators job is essential and this should be ensured.
For AFS-in-charges, safety training should include areas like:
i. Basics of safety management system
ii. The causes and effects of accidents
iii. Hazard identification
iv. Risk assessment and risk mitigation
v. Controlling risks and preventing accidents
vi. Emergency preparedness
vii. Critical task analysis
viii. Crisis management
ix. Importance of trip/alarm and safety procedures and systems
x. Learning from case histories

15.4 Training techniques

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from the use of OISD Standards/Guidelines.”
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Appropriate training techniques on the following basis should be selected and used in order to attain
the objectives of the various training courses outlined in this document:

15.5 Guidelines for Training co-ordinators

A) Course Objective:
The course objective should clearly and explicitly identify the outcomes a training programme is
expected to produce. For example, the aim of basic safety course is:
a) To provide good understanding and identification of the hazards associated with the job.
b) To provide clear understanding of the safe way to perform the job.
c) To evoke correct and prompt response in any emergency situation.
The objective of the course will be that on completion of the course, the trainee should be able to:
i. Recognise hazardous condition at his place of work;
ii. Perform his job in accordance with the safe operating procedure;
iii. Help rectify an unsafe condition;
iv. Escape safely in case of release of toxic gases;
v. Operate firefighting equipment etc.,

The more accurately and clearly the objective specifies the training outcome, the more helpful it will
be to co-ordinators and Faculties in designing their programmes. The objective of the programme
should be written down and communicated to the participants in the beginning.

B) Target Group:

The courses mentioned in this document are intended for different groups of persons. In a target
group, the academic background, proficiency in language likely to be used in a course and levels of
comprehension of subjects to be discussed may vary. Therefore, while inviting participants to a
course, it should be clearly stated what is the expected level of knowledge/experience that one should
have before he can derive full advantage of the intended course.

If the participants in a group are more or less at the same mental level of comprehension, then it is
easier to select the training technique that would be most useful for that target group.

C) Climate Setting:

Effective learning requires setting a climate in a training situation that is conducive to learning. The
following factors which help create such climate should be considered:
i. Persons are more open to learning if they feel respected and not being talked down to,
embarrassed or ridiculed.
ii. Participation in group exercises where trainees see themselves as mutual helpers rather than
rivals.
iii. Mutual trust and friendliness between trainees & faculty.
iv. Care of human needs such as peaceful environment, comfortable seats, adequate breaks
between training sessions, proper lighting and ventilation.

D) Course Design:

The course design should include following factors:

i. Programme layout
ii. Selection of faculty

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iii. Arranging course material/training aids

iv. Selection of training techniques
v. Field Visits: In case of new entrants, safety devices & procedures should be explained at site
also. Adequate time for field visits should be allotted. Field visits during refresher course may
also be arranged wherever necessary.
vi. Evaluation methodology

15.6 COURSE OUTLINE

This section specifies the minimum safety inputs to be included in safety or functional training course
for various categories of employees in selected areas through individual Course Modules.
Hazardous/high risk operation should be specifically highlighted indicating the risks and precautions.

The following points shall also be kept in view:

I) Safety Officers Training:

It is likely that a new incumbent may not have been exposed to the type of safety training prescribed
in this standard before taking up his assignment. It shall, therefore, be ensured that such persons are
also exposed to the relevant training programmes.

ii) OISD Standards, Guidelines and Recommended Practices.

The faculties shall use the relevant OISD Standards while presenting the topics listed in the
course contents, as given in the reference at the end.

15.7 Refresher Courses:

A number of refresher courses are listed hereafter. However, organisations themselves should select
the type of courses and decide how often the refresher courses should be held but the periodicity of a
refresher course should not be later than four years.

15.8 Industrial First Aid

Employees shall be imparted First Aid training by recognised agencies / Institute for development of
necessary skills. The requirement of minimum number of employees trained in a location shall be as
per statutory requirement. Refreshment training shall be arranged as per statutory rules/once in 3
years whichever is earlier.

15.9 SAFETY IN GENERAL MARKETING (POL)

All the employees and contractor workmen including TT crew members shall receive induction training
programme at the site. Visitors shall be given safety briefing before entry to the location.

15.9.1 Course Modules

Area: General Marketing (POL)

Course Code: 401

Intended For: Fresh Entrants (Officers & Supervisors) and transferred employees from other
locations

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Duration: 2 days

Objective: To provide knowledge on hazards associated with the job and safe way to perform
the job & to evoke correct & prompt response in any emergency situation.

Course Content:

i) Industrial Safety & Accident Prevention.

ii) Safety Regulations (Statutory and In-Company)

iii) Classification of Hazardous Areas

iv) Work Permit System

v) Hazardous Properties of Petroleum Products

vi) Fire - Causes, Prevention & Control

vii) Fire Protection Facilities - Operation & Maintenance

viii) Personal Protective Equipment

ix) Safety Instruments for Detection of Hazardous Atmosphere

x) Safety in Transportation of Aviation Fuel

xi) Safe Operation and Maintenance Procedures

xii) Housekeeping

xiii) Disaster Management Plan / Emergency Procedures/ drills.

xiv) First Aid session should be with simulated demonstration.

xv) Supervisor’s Role in Safety

xvi) Electrical Safety

xvii) Occupational Health Hazards

xviii) Near Miss and accident/incident reporting

15.9.2. Course Module

Area: General Marketing (POL)

Course code: 402

Intended For: All Officers and Supervisors (except those in sales) in Service

Duration: 3 days

Objective: To refresh and update knowledge on safety and handling of emergencies.

Course Contents:

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i) Industrial Safety in Petroleum Industry & Safety Regulation.

ii) Safety Regulations (Statutory and In-company) &Accident Prevention.

iii) Classification of Hazardous Areas

iv) Work Permit System

v) Hazardous Properties of petroleum Products.

vi) Fire - Causes, Prevention & Control

vii) Fire Protection Facilities Operation & Maintenance

viii) Personal Protective Equipment

ix) Safety Instruments for Detection of Hazardous Atmosphere

x) Safe Operation and Maintenance Procedures

xi) Safe Practices in Tank Cleaning

xii) Safety Audit

xiii) Housekeeping

xiv) Disaster Management Plan/Emergency Procedures / Drills

xv) Industrial First Aid

xvi) Supervisor’s Role in Safety

xvii) Electrical Safety

xviii) Occupational Health Hazards.

xix) Near Miss and accident/incident reporting

15.9.3 Course Module

Area: General Marketing (POL)

Course code: 403

Intended For: Officers handling Aviation fuel.

Duration: 1 day

Objective:

To update & refresh the knowledge on safety in Aviation operations

Course Content

i) Course Contents of Course Code 402

ii) Hazardous Properties of Aviation Fuel

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iii) Safe Operation and Maintenance Procedures with Special Reference to the Following:

a) Receipt Operations.

b) Refuelling

c) Work Permit System

d) Tank Cleaning.

15.9.4 Course Module

Area: General Marketing (POL)

Course Code: 405

Intended For: Office Staff

Duration: 1/2 day

Objective:

To provide knowledge on hazards associated with the job and Safeway to perform the job.
To evoke correct and prompt response in any emergency situation.

Course Content:

i) Hazardous Properties of Petroleum Products

ii) Fire-Causes, Prevention and Control

iii) Fire Fighting Facilities Operation & Maintenance

iv) Safety Regulations (Statutory and In-company)

v) Disaster management Plan/ Emergency Procedures/ Drill

vi) Industrial First Aid

15.9.5 Course Module

Course Code: 406

Intended For: Tank Truck Crew

Duration: 1 day

Objective:

To educate on safe driving and prevention of road accidents.

To evoke correct and prompt response in any emergency situation.

Course Content;

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i) Hazards of Petroleum Products.

ii) Safety in Transportation of Petroleum Products by Road

iii) Do’s& Don’ts in Transportation.

iv) Use of Fire Extinguishers, First Aid

v) Action in Emergency

vi) Safety in Loading/ Unloading Operations

vii) Tank Truck Fittings and Their use

viii) Upkeep of Safety Equipment Provided with Transport Vehicle

15.9.6 Course Module

Course Code: 407

Intended For: Workmen at Field Location including contractor staff

Duration:1 day

Objective:

To provide knowledge on hazards associated with the job and safeway to perform the job.

To evoke correct and prompt response in any emergency situation.

Course Content:

i) Hazardous Properties of Petroleum Products.

ii) Safe Operating Procedures

iii) Fire-Causes, Prevention and Control

iv) Fire Protection Facilities-Operation & Maintenance.

v) Personal Protective Equipment

vi) Housekeeping.

vii) Emergency Procedures /Drills

viii) Industrial First Aid.

15.10 Evaluation of safety training programme.

The evaluation of safety training programmes in terms of their overall effectiveness towards
attainment of course objectiveness and changes necessary for improvement, should be based on the
criteria and techniques explained in the OISD 154.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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15.11 Records of training.

Safety training needs of persons can be assessed only if relevant information is readily available.
Records of training, therefore, should be maintained in respect of every employee indicating the types
and the period of training programmes attended, performance evaluation (Ref. OISD 154 for details).

16 SAFETY AUDIT

16.1 GENERAL

Safety audit is a well-recognised tool to improve the effectiveness of safety programme and loss
prevention measures by carrying out systematic and critical appraisal of potential safety hazards
involving personnel, plants and equipment.

For a structured and systematic safety audit of any plant/ facility, check lists are the most important
prerequisite. Check lists should cover all the operational areas, major equipment, operating/
maintenance procedures, safety practices, fire prevention/ protection systems etc. Observations/
recommendations of safety audit team should be presented in the form of a formal report and action
plan for corrective measures should be prepared and subsequently monitored for implementation.

General guidelines on safety audit methodologies and techniques are also given in OISD - GDN- 145.
16.2 Objective & scope of Safety Audits:

a) Introduction

Identification of vulnerable areas and specific potential hazards is one of the prime functions of loss
prevention in oil industry. Safety audit is an important tool in undertaking this function.

b) Objectives of safety audits

While the basic aim of safety audits is to identify the areas of weaknesses and strengths, safety audits
are undertaken to meet different specific objectives viz.-

i. To identify any design deficiencies and also any weaknesses which might have cropped up
during modifications / additions of facilities.

ii. To ensure that fire protection facilities and safety systems are well maintained.

iii. To ensure that operating / maintenance procedures, work practices are as per those
stipulated in the manuals and standards, which might have degraded with time.

iv. To check on security, training, preparedness for handling emergencies and disaster
management etc.

1. To check on mutual aid scheme, preparedness practice with district authority/fire brigade.

2. To check the compliance of statutory regulations, standards, codes, etc.

v. As a social objective to cater to public opinion and concern for safe environment. This also
improves public relation of the organization.

c) Scope of safety audits

A Safety Audit subjects various areas of a company's activities to a systematic critical examination
with the objective of minimizing loss. This includes all the components of the system viz. management

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policy, attitudes, training, design aspect (Process, Mechanical, Electrical, etc.), layout and
construction of the plant, operating Inspection & Maintenance procedures, emergency plans, personal
protection standards, accident records.

d) Types of safety audits

Two types of Safety Audits are proposed to be carried out as below:

I) Internal Safety Audit

ii) External Safety Audit

Audit conducted by Internal Audit teams of the organization is categorized as Internal Safety Audit.
Internal Safety Audits will be coordinated by local management under the overall direction from the
respective Corporate Offices.
External safety audits will be carried out by outside teams consisting of technical experts from other
organizations in Oil Industry, professional bodies and statutory authorities under the overall
coordination of OISD.

16.3 Methodology of internal safety audits

a) Frequency of audits:

The facilities in an AFS should be covered minimum once every year. However, facilities' design can
be audited every 3 years or after any major modification or additions. For this purpose, the individual
organisation/ installation should draw up a calendar in advance for carrying such audits for every
calendar year which should be made known to all the Departments and concerned Managers. The
areas to be audited should be clearly identified and logically grouped.

b) Duration of audit

Depending on the nature of audit and type / complexity of the installations in the selected group, the
duration of internal safety Audit can be fixed. This may vary from 1 to 2 working days for facilities
under each group.

c) Use of safety audit check lists

Check lists are the most useful tools for undertaking systematic Safety Audit. Even for a skilled and
well qualified engineer a good check list would be necessary as a guide. Like a code of practice, a
Check List is a means of pooling the knowledge and hard won experience and ensures that no
important aspect is overlooked or forgotten. Such check lists help maintaining uniformity and
speeding up the audits.
At the end of this section area specific sample checklist is given and that maybe further developed
based on the facilities in the AFS.

d) Preparation before site visits for internal safety audits.

The safety Audit team visits any particular facility for carrying out Safety Audit, it would be essential to
study all relevant documents as below to get complete picture:

1. Layouts
2. P & IDs
3. Operating Manuals/”SOP”
4. Maintenance. / Inspection Manuals/records.
5. Fire and Safety Manuals, etc.

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from the use of OISD Standards/Guidelines.”
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6. Earlier internal audit /external inspection reports

Depending upon the nature of audit more emphasis can be given to study specific documents. All the audit
team members should study these documents in advance to know the details of the installation.

e) Briefing:

Before beginning of each audit, all concerned persons of the area/installation are briefed by the team
leader about the purpose of the audit. No impression should be left that audit will throw bad light on
them.

f) Site inspections:

Most of the information could be gathered through site inspection using ready-made check lists. The
auditors should enter their observations under the remarks column and not simply state "yes" / "no".
Wherever necessary, observations should be recorded in separate sheet. Inspection should be
carried out accompanied by Installation Manager/In-charge or the assigned officials.

g) Discussions:

Further information can also be gathered through discussions (formal & informal), with site personnel
and AFS in-charge or other officers. The audit team should interact with persons from various
disciplines such as Operations, Maintenance, Electrical, Instrumentation, etc.

h) Study of documents:

In addition to the documents which are already studied before inspection of the facilities, other
documents, such as standard Operating Instructions, Standing Orders, Log Books, Log sheets,
Accident Records, Minutes of Safety Committee Meetings etc. may also be studied as required.

i) Preparation of audit reports:

The work of the Internal Safety Audit item should be presented in the form of a Safety Audit Report
for each group which should contain observations & recommendations and also in brief the modalities
adopted in conducting audit and the names of the audit team member/s.

The audit team shall finalize the audit report based on the discussions with auditee/location-in-charge.

j) Follow up of audit reports:

Generally, the Internal Safety Audit Reports are submitted to the concerned authority who appoints
the audit team for undertaking needful follow up actions. Only the appointing authority should
exercise judgement in rejecting any of the recommendations. The crux of the safety audits lie in
removing the weakness identified during the audit.

In such cases, it would be necessary to undertake a detailed study of the specific area and to identify
the rectification measures. Wherever the necessary in-house expertise is not available for detailed
studies, help of consultants / professional bodies should be sought for.

k) Implementation of recommendations:

The final and most important phase is the implementation of recommendations. A senior person
should be nominated for coordinating implementation of all accepted recommendation under a time
bound program. Senior management should review the progress of implementation of

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recommendations periodically through Management Safety Committee meetings and other review
meetings.

l) Various Audits and frequency of Audits.

Check List
S.No. Type of Safety Audit By whom Frequency
Annexure
Safety walk around Designated Safety
1 Daily/Weekly Annexure 6
checks of AFS officer (DSO)
Safety inspection of Monthly/Quarterly/Half
2 In-charge AFS Annexure-6
AFS yearly
Accredited electrical Once in 4 years or as
Engineers per statutory
3 Electrical audit Annexure-7
/Authorised Class A requirement whichever
Electrical engineer is earlier.
As per OISD-
4 Internal safety audit HS&E representative Yearly
STD-145
Before commissioning
and any major addition
Pre-commissioning OISD Pre-Com
5 OISD/As applicable of facilities such as
inspection check list
increase in storage or
despatch facilities.
Two inspections at an
External safety audit interval of 5 years, OISD ESA
6 OISD/As applicable
(ESA) there after a request check list
audit.
7 Surprise inspection OISD/As applicable As and when decided Random Checks
Officers of the level
of Executive Director/
Special Inspection by Two major installations
8 General Manager of Random Checks
senior officers per year
respective oil
company.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Annexure-1:

Critical Alarm Levels’ logic in Tank

Overfill Level
______________________________________________

Safe Fill Level (HH)

_______________________________________________

High Level (H)

_______________________________________________

Normal fill Level

_______________________________________________

Note: Settings to be such that under no circumstances the Safe Fill level is exceeded.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Annexure: 2
Checklist for Bulk ATF Tank Trucks at AFS:
Sr Item Remarks
No
Daily Checks
1 Whether valid licence, Fitness, Calibration and explosives
certificates are available in the vehicle?
2 Whether the vehicle has two fire extinguishers (9/10 kg DCP)?
3 Whether there are any sources of ignition like matches etc. in the
vehicle?
4 Whether the vehicle has at least a driver and a cleaner as its crew
member?
5 Whether the driver has a valid driving licence with endorsement for
having undergone training for carrying hazardous goods as per
Motor vehicle act.
6 Whether approved quality flame arrester provided on the engine
exhaust and muffler/silencer is properly bolted without any leaks?
7 Whether each compartment of tank is fitted with independent
vacuum and pre-operated vents (PV Valve)?
8 Whether vehicle’s cabin is checked for presence of any
flammable/explosive substance being carried by the crew?
Additional Checks:
9 Whether the vehicle has a cut off switch for electrical system?
10 Whether there is facility to shut off the drain valves in case of
emergency?
11 Whether the vehicle has First Aid Box, Tool Box?
12 Whether the driver has a copy of standing instructions and TREM
card?
13 Whether the exhaust is wholly in front of tank truck and has ample
clearance from fuel oil system and combustible material.
14 Whether all electric wiring is properly insulated?
15 Whether all junction boxes are sealed properly?
16 Whether electrical equipment like generator switches, fuses and
circuit breakers are located inside the cabin or engine
compartment?
17 Whether battery is in easily accessible position with a heavy duty
switch close by, to cut off the battery in emergency?
18 Whether battery terminals have protective rubber covers?

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Annexure-3
MAINTENANCE SCHEDULE OF CRITICAL EQUIPMENT

MAINTENANCE SCHEDULE
CENTRIFUGAL PUMP

Sln. Equipment Parameters to check Periodicity

Weekly Monthly Quartely
1. Check lub oil & top up level if necessary.
Check cooling water flow (where provided).
2. Check mechanical seal/ gland leakage.
3. Check the "AMPS" are within limits
4. Change lube oil every 800 running hours.
5. Check coupling and coupling bolts and replace worn out
parts.
6. Check tightness of foundation bolts.
7. Clean suction strainer of :
a) Product pumps
b) Other pumps
8. Check alignment of pump and motor.
9. Overhauling
10. Greasing of Bearings.
11. Check alignment of pump and motor
12. Vibration Analysis

DIESEL ENGINES
MAINTENANCE STEPS

1. Keep the dirt out of the engine.

2. Maintain a lubricating film on all bearing surfaces.
3. Regulate the engine's fuel.
4. Control operating temperatures.
5. Guard against corrosion.
6. Let the engine breathe.
7. Prevent over speeding.
8. Know your engine's condition.
9. Correct troubles while they are simple.
10. Schedule and control your maintenance.

Diesel Engines:
“A” Daily Checklist
Sln. Maintenance Steps Remarks
1 Check previous day's engine log book. Correct as required
2 Drain water and sediment from fuel tank and Before starting engine.
fuel filter through drain cock.
3 Check engine oil level and top up if necessary Must be slightly less than or equal to "h" mark on dip stick
when engine is stopped and has stood for 20 minutes or
more (must be measured after all oil is drained back into oil
pan).
4 Check for fuel,oil,water Correct if leaking.

5 Fill radiator/surge tank with treated water Radiator cap must be firmly tightened back into the
(Chromate concentration 3500 ppm). radiator/surge tank neck engine must not be operated

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without the radiator cap since this will cause aeration and
overheating of the coolant.
6 Check air cleaner oil level and change oil, Use clean engine oil
if required (if oil bath type) clean dust pan
and pre cleaner of day type air cleaner.

7 Check air line connections for leaks Correct as required

8 Remove and clean air compressor Fill with clean oil, upto mark.
breather, if equipped.
Drain air receiver tank at the beginning of
each shift and then close the drain cock.
Clean crankcase breather Discard paper type element, if clogged.
Check oil level in hydraulic governor, if Check for leaks, use specified engine oil for topping
provided. up.
Start the engine and note the oil If there is a change in oil pressure from that recorded
pressure both at idling and maximum in the long book on earlier occasion then stop engine
speed and check through trouble shooting technique the
cause for oil pressure change and correct if necessary
(for assistance in diagnosing the change in oil
pressure call your service representative if necessary.
Record oil pressure Refer O&M Manual for Lube Oil pressure limits.
Fill fuel tank at the end of the shift. Use clean fuel and a strainer. Also clean the cap and
surrounding area before opening the filler cap.

Note: In addition, Diesel Engine “B”, “C”,”D” and “E” checks shall be carried out as
per manufacturers guide lines

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Annexure-4

Format for Request for Management of Change

Location ______________
Request No. : __________ Request Date _____________

1. Description of Proposed change : Request Date: __________

2. Technical Reason for the proposed change :
3. 1. Description
Potential of Proposed
benefit after change
effecting the change: :
4. 2. Technical
Impact Reason
of the proposed for the
change onproposed
: change :
3. Potential
a) Safetybenefit
[HAZOPafterfindings,
effectingifthe change :
applicable]
4. Impact of the proposed change on :
b) Health
a) Safety
c) Work [HAZOP findings, if applicable]
Environment
b) Health
d) Product Quality
e) Anyc) other
Workaspect
Environment
5. Compliance d)statusProduct
to OISDQuality
& Statutory Regulations :
e) Any other
6. Nature of Change : Temporary aspect Permanent Normal Emergency
5. Compliance status to
7. Revised documents as applicable OISD: & Statutory Regulations :
6. Nature
a) P&IDof Change
Drawing : Temporary Permanent Normal Emergency
7. Revised documents as applicable :
b) Layout Drawing
a) P&ID Drawing
c) PFD Drawing
b) Layout Drawing
d) SOP
c) PFD Drawing
8. Change of manpower
d) SOP :
a) No.ofofmanpower
8. Change new personnel
: :
b) Category
a) No. of[ Officer / BCW / WCW
new personnel : ]:
c) Details of training[imparted
b) Category Officer /on the new /role
Operator :
Clerical ]:
c) Details of training imparted on the new role :
___________________________________ ___________________________________
Name, Designation, Emp. No. Of Initiator Signature of the Initiator

____________________________ _____________________
Name & Designation of Initiator Signature of the Initiator

______________________________________________________________________________
Comments of the Reviewer

____________________________ _____________________
Name & Designation of Reviewer Signature of the Reviewer

_____________________________________________________________________________
Comments of the Approver

____________________________ _____________________
Name & Designation of Approver Signature of the Approver

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from the use of OISD Standards/Guidelines.”
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from the use of OISD Standards/Guidelines.”
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Annexure-5
Delegation of Authority (DOA) for MOC :Aviation Fuel Stations
Sl. # Category of Details of Change Addl. Initiator of Reviewer Approver Post-
Changes Requirement / MOC Request execution
Remarks Inspection for
confirmation
1 Facility Augmentation of Storage Tanks of product. Risk
Assessment
2 Facility Modification in Piping system – sizing / Risk
routing / Pressure Relief ratings / type & Assessment
specs of valves
3 Facility Modification in Pumps – addition / deletion, Risk
Changes in capacity , Changes in suction / Assessment
discharge piping configuration
4 Facility Addition / modification of facilities – --
Administrative block, laboratory, boundary
wall, Utility sheds, Utility water pumps etc.
5 Facility Changes in Electrical Systems – transformer Electrical
rating, new DG set, synchronisation of load Audit
etc.

6 Facility Handling of Additional Product Grades Risk

excluding Lubes & associated fuels/ additives Assessment

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Sl. # Category of Details of Change Addl. Initiator of Reviewer Approver Post-

Changes Requirement / MOC Request execution
Remarks Inspection for
confirmation
7 Operating Any changes in operating procedures other Risk
Procedure than that given in Aviation Operation Manual, Assessment, if
approved SOPs or, convention followed in the felt necessary
location. Probable examples : by Designated
Line-up for PLT, receipts / deliveries thru’ Safety Officer
TT/ TW, Gauging of Tanks, Water Draining,
Calibration of TTs &Flowmeters, refuelling
ops. thru refuellers/hydrant dispensers, etc.

8 Operating Changes in operating procedure other than --

Procedure given in Aviation Operation Manual to
comply newly amended statutory &
regulatory norms or recommendations from
authorities.

9 Operating Any change / additional new operations --

Procedure involving maintenance of product storage
tanks, refuellers, tank repairs, cleaning of
tanks, quality control procedure, etc.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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10 Operating Any change in inventory accounting practices --

Procedure including pipeline qty., calculation modality,
calibration chart etc. In variance with
Accounting Manual / Aviation Ops. Manual.

11 Facilities Any changes in software, ERP system / --

invoicing / documentation and computer
hardware changes affecting operating
processes
Sl. # Category of Details of Change Addl. Initiator of Reviewer Approver Post-
Changes Requirement / MOC Request execution
Remarks Inspection for
confirmation
12 Facilities Any changes in automation set points, logic, Opinion of
processes, calibration / accuracy requirements TAS/TFMS
for SCADA, TFMS & other IT systems vendor, plus
Risk Asses. if
required by
Safety Officer
13 Operating Cleaning / Repairs of the Fire Water Storage Risk
Procedure Tanks Assessment by
Designated
Safety Officer
14 Operating Change in working hours / Addition/Deletion --
Procedure of shifts
15 Facilities Upgradation of refuelling facilities and --
equipment in line with new API/EI
specifications.

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from the use of OISD Standards/Guidelines.”
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Note:
Designations of requisite authority for initiator, reviewer and approving authorities shall be assigned by respective OMC depending
upon the MOC items’ relevant functional areas. However the logic of successively higher authority levels for the 3 stages viz.
initiator, reviewer and approver shall be maintained.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Annexure-6
Check Lists
Safety Audit Check List – AFS
Location ______________
Audit/ Inspection by _________________
A. Fire Protection System & Security check

Item Frequency Observations Action taken in brief (if

any) with date.
Check water level in static water
tanks and record in the log book. Daily

Ensure pump suction & discharge Daily

valves are full open.
Check functioning of water tank Weekly
level gauges
Check & record hydrant line
pressure in the log book Daily
Periodical health checkup of Monthly
batteries and maintain record
Check fuel level in the fire engine Daily
fuel tanks & record.
Check functioning of fuel level weekly
indicators.
Check condition of engine exhaust Monthly
insulation lading.
Run one pump & ensure all the Daily/weekly
pumps are run at least twice in a
week and record pressure
developed & operating parameters
in the log book
Whether engine trip mechanism is Monthly
in working condition.
Simulation testing of fire engine Weekly
auto start with pressure drop in
hydrant and Engines starts in
sequential order as per displayed
philosophy.
Check functioning of exhaust fans Weekly
in a covered pump house to Check
effectiveness of ventilation.
Check Fire siren range (3 km) and Monthly
hand sirens are in strategic place.
Whether emergency / DC supply Daily
continuously available for fire
siren?
Surprise check if frisking of crew Daily
members /visitors/contract
workmen are done at entry gate
and record maintained.
Check proper functioning Daily
DFMD/HH metal detectors at gate
are.
Check functioning of CCTV system Daily
& record deficiencies, if any?

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from the use of OISD Standards/Guidelines.”
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Security check for integrity of Daily

boundary wall/fence?
Safety officer to review Weekly
Random Check if any vehicle with Daily
Spark ignition engine is allowed in
the hazardous area and vehicles of
IC engines are fitted with proper
exhaust.
Check work permit in random for
the ongoing jobs in the location,
whether the same in line with Daily
relevant OISD STD and intended
jobs.
Check presence of supervisor &
adequacy of firefighting system.
Deviations to be recorded & report
to location I/C
Check effectiveness of Weekly
communication between various
operating areas functioning &
record deficiency.
Random Check of emergency gate Daily
for any obstruction.
Check for Caution signs & speed Quarterly
limit display at appropriate places.
Whether control room is manned Daily
continuously / during operations?
Random check if persons entering Daily
/working at hazardous areas are
using PPEs?
Check for any accumulation of oil Weekly
in the drains connected to OWS
Randomly check if OWS outlet Weekly
drain valve is closed
Whether OWS functioning is Monthly
effective and final discharge free of
Oil?
Check illumination level at all Quarterly
operating areas after sun set &
record the lux level.
Check if Portable fire extinguishers Monthly
are placed as per OISD 117?
Check proper functioning of Monthly
hydrant/monitors in the location.
Check / test of sprinkler system Half yearly
and records performance.
Check/test of foam pourer system Half yearly
and record performance.
Whether foam quantity is adequate Monthly
and meets requirement.
Check deployment of foam drums
at field and stored as per OEM
recommendation.
Comments on housing keeping Weekly
Any other observations? ---

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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B. Bulk storage area – Tank Farm

1 Check if product tank water drain Weekly

line ends are blanked off when not
in use.
2 Check if dyke drain valve kept in Daily
closed position?
3 Check functioning of dyke drain Monthly
valve position indication in C/room
for effectiveness of its working.
4 Check for rigidity of earthing Monthly
terminal connections.
6 Whether tank level instruments are Quarterly
in working condition?
7 Visual inspection of product Monthly
storage tanks for any sign of
leakage / sweating /valve gland
leakage etc.
Check the floating roof deck for
any excessive vapour
accumulation/leakage/abnormality Weekly
etc.
8 Whether any settlement of tank, Monthly
cracks on pad observed?
9 Whether ROSOV on tank delivery Weekly
line on remote mode?
10 Whether dyke area & underneath Monthly
of manifold are free from any oil
leakage / accumulation.
11 Whether isolation valve for TSV / Monthly
expansion line kept open to
facilitate taking care of expansion
12 Whether Bonding across flange Quarterly
joints and floating roof deck are
rigid.
13 Whether escape pathway from Quarterly
tank farm is free from obstruction?
14 Whether road round the dyke is Daily
free from any obstruction?
15 Whether Housekeeping in order? Monthly
16 Any other observations? ----- -----

C. Truck/refuellers loading / unloading gantry

1 Random check for TT /refuellers Daily

speed limit (10 KMPH) inside the
premises
2 Whether crew members are Daily
carrying proper I-cards? (Random
check)
3 Whether spark arrestors are of All TTs in
make and design approved by each
PESO? (Random check) Quarterly
4 Whether TT/refuellers engine and Daily

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from the use of OISD Standards/Guidelines.”
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master switch being switches off

after placement at gantry & wheel
chocks are used.
Random check of TT/refuellers All TTs in
cabin for presence of any match each
stick/flammable substances etc. Quarterly
5 Random check for TT earthing on Weekly
clit of TT body and not on mud /
guard / valve / cabin.
6 Whether swing ladders are safe for Monthly
operations and has neoprene pad
to avoid metal to metal contact?
7 Random check for product leakage Weekly
from valve / flanges / swivel joints
etc. Check TT/refuellers manifold
valves for any leakage during
loading.
8 Whether removal of excess filled Weekly
product from TT compartment is
safely handled?
Check if any loose product is
stored in the gantry in drums /
buckets etc.
9 Whether gantry area is free from Daily
oil spillage and housekeeping is
good?
10 Whether operating personnel are Daily
carrying walkie-talkie, wherever
provided?
11 Whether the emergency shut off Quarterly
switch for pumps is functional?
12 Whether approach to gantry Monthly
isolation valve is free from any
obstruction?
13 Whether approach to hydrant / Monthly
monitors around gantry are free
from any obstruction?
14 Random Check if portable FE are Daily
placed at designated area & easy
accessible area before loading of
TT
15 If hoses are used, visual check of Monthly
hose condition.
16 Check whether periodical testing At defined
(hydro test& electrical continuity frequency.
test) of hoses are due.
17 Whether hoses are secured Daily
properly in the gantry after loading (Random)
operations and do not obstruct TT
movement in the gantry?
18 Whether emergency escape is Quarterly
marked with signage / display and
approach is free from obstruction?
19 Any other observations? -----

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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D. Product Pump House (loading / unloading)

1 Whether electrical termination in Monthly

the JBs is apparently sound?
2 Whether earthing / bonding Monthly
connections are apparently sound?
3 Whether pressure gauges on Monthly
pumps / compressors are in
working condition?
4 Whether pump motor coupling Monthly
guards are in position?
5 Whether connected drain line Monthly
valves on strainer / line are closed
& caps in position?
6 Whether valves for product Daily
circulation are cracked open for
loading operations?
7 Whether any abnormal vibration Daily
excessive noise from pumps
motors noticed?
8 Whether any visible sign of product Daily
leakage from valves / flanges /
seals or any unsafe conditions
observed?
9 Whether strainers are periodically Quarterly
cleaned and written?
10 Whether valve operating platforms Monthly
are kept free for easy movement?
11 Whether Housekeeping in order? Monthly
12 Any other observations? ----

E. Laboratory

1 Whether earthing connection Monthly

terminals are apparently rigid
2 Whether laboratory electrical Quarterly
fittings are Industrial type closed /
tight metal clad fittings for plug and
socket assembly?
3 Whether main electrical circuit is Quarterly
provided with ELCB?
4 Whether samples of Class ‘A’ Daily
petroleum products are kept in
airtight containers?
5 Whether sample containers are Weekly
stacked properly?
6 Whether sample room is free from Daily
Oil spillage?
7 Check functioning of exhaust fans Weekly
in sample room.
8 Whether “No smoking” board Quarterly
displayed?
9 Whether Housekeeping in order? Daily
10 Adequate fire-fighting facilities are Daily
available or not?

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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11 Any other observations? ---

F. Transformer yard

1 Check if gate of transformer yard Daily

kept closed.
And entry of persons other than
authorized person is under
supervision.
2 Check if entry of persons other Daily
than authorized person is under
supervision only.
3 Transformer Grounding OK Monthly
4 Any visible oil leak observed. Daily
5 Silica gel condition ok Monthly
6 Transformer Oil level ok Monthly
7 Oil / winding temp ok Monthly
8 Whether earthing & bonding of Monthly
yard fencing is ok.
9 Whether danger board is Monthly
displayed?
10 Whether proper rated hand gloves Monthly
available and periodical testing is
not due.
11 Whether Housekeeping in order? Daily
12 Any other observations? ----

G. Electrical Sub Station/ Switch room

Sin Item Observatio Item Observation

n
1 Check if any unauthorized Daily
electrician/person handles the
electrical system.
2 Whether earthing / bonding Monthly
connections are apparently sound?
3 Whether updated single line Half yearly
diagram is available?
4 Whether proper rating insulating Half yearly
mats are provided?
5 Check functioning of sub Station Weekly
/MCC room Exhaust fans for
effective ventilation.
6 Check if any temporary electrical Daily
connection exists.
7 Check presence of Dust / soot / Quarterly
cobwebs in the panel
8 Check availability of proper rated Monthly
hand gloves, validity and its use.
9 Whether Housekeeping in order? Daily
10 Any other observations? -----

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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H. TT Checks required to be carried out on random basis by Officer (Total no of TTs plying in
location shall cover in a quarter):

1 Whether driver undergone training Quarterly

on “safe driving practices” &
“transportation of hazardous
goods”?

2 Comments on assimilation of Quarterly

above training / knowledge.

3 Whether crew members possess Quarterly

TREM card / detailing instructions
on handling emergencies en route
and understand the contents?

4 Whether master switch control is Quarterly

easily accessible to enable
electrical circuits to be isolated and
fitted close to Battery?

5 Whether batteries are effectively

protected against contact with any Quarterly
spillage of flammable liquid and be
fitted with an insulator cover to
protect against inadvertent contact
by objects which could cause a
spark?
6 Electrical wiring is insulated and Quarterly
provided with suitable over current
protection in the form of fuses /
automatic circuit breaker etc have
been provided.`
7 Exhaust is wholly in front of the Quarterly
TT? Whether spark arrestor of
make and design approved by
PESO is properly fitted and
Exhaust is wholly in front of the
TT?
8 Check that all electrical wiring Quarterly
through conduit pipe and there is
no loose connection. All junction
boxes are properly sealed.
9 Whether Vehicle Management Quarterly
System, Security locking system in
place?
10 Whether TT is carrying a fully Quarterly
equipped first aid box and FLP
emergency light?
11 Whether proper safety fittings (PV Quarterly
vent, Master valve, fusible link etc.)
are in place? Check the testing
certificate of PV vents.
12 Whether TT is having any visible Quarterly
dent on the body?

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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13 Whether any visible leak observed Quarterly

from valves / flange joints?
14 Check for ladder at rear end and Quarterly
catwalk are intact and in position.
15 Check that width of tank body is Quarterly
less than cabin width.
16 Whether fire extinguishers are ISI Quarterly
approved and periodical testing /
refill are carried out?
17 Demonstration by crew members Quarterly
on operation of fire extinguishers.
18 Check for valid PESO license and Quarterly
authenticated copy of tank truck
drawing.
19 Check adaptation of roll over Quarterly
design for protection of manhole
fittings in case of TT overturning.
20 Check for Calibration certificate, Quarterly
physical verification of dip rod for
correctness of dip marking,
condition W & M seals on
manholes.
21 HAZCHEM sign, name of Quarterly
contractor with address and
telephone No. displayed
prominently.
22 Random check, during TT Quarterly
calibration, the compartments are
fittings are fabricated in line with
OISD STD 167. Any deviation shall
be recorded and rectified
immediately.
23 Any other observations? -----

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Annexure-7
ELECTRICAL AUDIT OF AFS
LOCATION _____________ Dated ____________
AUDIT/ INSPECTION BY ______________________
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
---------------------------------------------------------------------------------------------------------------------------
A. ELECTRICAL SUBSTATION/ SWITCH ROOM
A-01 Is line diagram of power/ lighting distribution and shock chart provided.
A-02 Is the equipment easily accessible for operation, inspection & maintenance.
A-03 MCC Panel condition :
a) Doors okay and closed
b) Dust/soot/ cobwebs not existed
c) Lugs existing at each cable, termination not loose.
d) Visual condition of switch contact fuses etc. O.K.
e) Control wiring condition satisfactory.
f) Jumper condition between bus and distribution okay.
g) Grounding OK
h) Alarm/ trip circuit working.
A-04 Live parts of equipment made inaccessible by barriers/ shrouds.
A-05 No temporary electrical connection existing.
A-06 Condition of cable duct
a) Cables are on rack
b) Cable deck clear
c) Sealing of duct
d) Cable identification tags.
A-07 Insulation mats (with ISI mark) existing are enough in number.
A-08 Protective relays set at recommended values.
A-09 All fuses are of proper type and rating as specified in single line diagram.
A-10 Fire extinguishers are of proper type and are in working condition.
A-11 Lighting condition OK (fixtures/ tubes/ switches etc.)
A-12 Emergency lighting system in order.
A-13 All energized equipment provided with caution boards.
A-14 Condition of transformer:
a) Grounding OK
b) No oil leak
c) Silica gel OK
d) Oil level OK
e) Terminal box earthing OK
f) Oil/winding temp. OK
g) Periodic oil quality test conducted.
A-15 Whether location/type of transformer in conformity with area classification drawings.
A-16 Housekeeping is good.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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B. MOTORS IN PUMP HOUSE/ COMPRESSOR ROOM

B-01 Is double independent earthing connection for all motors provided.

B-02 Is grounding wire OK (not loose).
B-03 a) Is terminal box and gland OK Flame-proofness maintained and not tampered.
b) Existing cable termination are proper
B-04 a) Is push button earthed properly and flame proof condition not tampered.
b) General condition of push button good.
B-05 Ground resistance at motor/ push button measured and found okay.
B-06 No motor abnormality Vibration/ bearing condition, faulty guard, fan condition,
excessive noise, high body temperature.
B-07 Existing preventive maintenance schedule OK.
B-08 a) Earthing resistance test schedules/ records satisfactory.
b) Earthing pit condition OK
B-09 First-aid chart for treating electrical shocks displayed prominently in MCC room.

C. UNIT LIGHTING

C-01 All lighting fixture flame proof as per area classification.

C-02 Whether flame proof condition of fixtures ensured ?
C-03 Whether proper earthing of fixture provided ?
C-04 Condition of wiring good.
C-05 Does water enter and accumulate in fixture distribution boxes etc ?
C-06 Whether lighting DB, switches, MCB well maintained ?
C-07 Any other unsafe point observed.

D. MAST LIGHTS (AREA LIGHTING)

D-01 Whether grounding of mast OK ?

D-02 Condition of junction boxes, switch board, fuses etc. OK
D-03 Approach to electrical installation and ladder good and safe.
D-04 Condition of flood lights :
a) Is gasket present ?
b) Is glass cover in good condition ?
c)Is control gear condition OK
D-05 Is earthing electrode of mast OK and its connection with mast proper ?

E. TANFARM AREA, PIPELINES, LOADING/UNLOADING GANTRY

E-01 Are pipelines provided with flange earth jumper connection for electrical continuity?
E-02 Are earthing provision on storage tanks well maintained ?
E-03 Condition of grounding electrode OK
E-04 Continuity of location, hoses maintained.
E-05 Grounding resistance at inlet of grounding connection checked/ date
E-06 Connection of earth-bonding of railway track OK.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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F. GENERAL
F-01 a) Area classification drawings duly approved by PESO?
b) Conditions if any, specified by PESO for electrical substation, switch room etc. and
their compliance.
F-02 Certificate in respect of FLP for each electrical equipment- records maintained.
F-03 Earthing network diagram available and site checks done from time to time.
F-04 Records for electrical testing/ checks maintained upto date.
F-05 Work permit system is effective and records are maintained.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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ANNEXURE : 8 CHECK LIST FOR AFS

GroupCode Area Observation Recommendation

Sno Audit_Particulars
Part-A SAFETY Whether safety policy
MANAGEMENT 1.01 approved by Management
available.
Part-A SAFETY Whether policy displayed
MANAGEMENT 1.02
in prominent location.
Part-A SAFETY Whether declared
MANAGEMENT /approved safety policy is
1.03
made available to all
concerned in written form.
Part-A SAFETY Whether policy
MANAGEMENT disseminated to –
1.04
a) Officers
b) Non-Management Staff.
Part-A SAFETY Whether any system
MANAGEMENT prevails to have proper
monitoring/
1.05
feedback/suggestions on
safety issues by
appropriate authority.
Part-A SAFETY Whether safety slogans are
MANAGEMENT 1.06 displayed at strategic
locations.
Part-A SAFETY COMMITTEE. Whether any safety
2.01 committee is in existence
in the location.
Part-A SAFETY COMMITTEE. Whether sufficient
representation from non-
2.02 management cadre exists
in the committee as per
Factory Rules.
Part-A SAFETY COMMITTEE. Whether meetings are
2.03 conduct at least once in a
quarter.
Part-A SAFETY COMMITTEE. Whether safety committee
meetings are chaired by
2.04
the location in-charge or
his nominee
Part-A SAFETY COMMITTEE. Whether committee
reviews the earlier
decisions and action points
2.05 are recorded with target
dates with person
responsible for
compliance

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Part-A SAFETY COMMITTEE. Whether only safety

related issues are discussed
in the meeting (Records
for last 2 years meeting to
2.06
be checked and interaction
with safety committee
members to ascertain their
perception)
Part-A SAFETY TRAINING Whether regular training
courses are conducted for
all staff including
3.01 contractor staff on safety
and firefighting. If yes,
no. of such programmes
organised in last one year.
Part-A SAFETY TRAINING
No. of participants on
safety programmes from
the location in above
mentioned courses.
a) Officers (including new
3.02
entrants/trainees)
b) Non-management staff
c) Security staff
d) Tank truck crew
e) Contractor’s workmen

Part-A SAFETY TRAINING Whether course modules

are framed as per OISD
154 in relevance of
3.03
location requirement
(company as well as
contractors ‘staff)
Part-A SAFETY TRAINING No. of Heavy Vehicle
Drivers are trained as per
3.04 Airport authority
requirements in last two
years.
Part-A SAFETY TRAINING Whether First Aid Training
imparted to staff by
Authorised Agencies in
3.05
line with Factories Act
(minimum 20% of total
employees)
Part-A SAFETY TRAINING Comments on assimilation
of safety training in respect
of –
3.06
- Officers
-Non-management staff
- Contractors’ Workmen
Part-A SAFETY TRAINING
Whether refresher courses
3.07 are organised periodically
for improvements.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Part-A EMERGENCY
MANAGEMENT Whether fire organisation
SYSTEMS chart covers all aspects for
4.01
a) On shift,
b) Off shift hours.
Part-A EMERGENCY Whether fire drills are
MANAGEMENT 4.02. conducted regularly. What
SYSTEMS is frequency?
Part-A EMERGENCY
Details of Mock fire drill
MANAGEMENT 4.02.01
during this ESA.
SYSTEMS
Part-A EMERGENCY Whether shortcomings
MANAGEMENT recorded and remedial
4.03
SYSTEMS actions taken for
improvement of fire drills.
Part-A EMERGENCY Whether mutual aid
MANAGEMENT scheme is available. If
SYSTEMS yes, whether the same is
4.04
discussed periodically with
members and records
thereof are available.
Part-A EMERGENCY Whether well-defined
MANAGEMENT disaster control plan (on
SYSTEMS site/off site) is available
for the location and
4.05
approved/acknowledged
by Factories
Inspector/defence
authority.
Part-A EMERGENCY Whether Disaster
MANAGEMENT Management Plan is
4.06
SYSTEMS prepared based on risk
analysis.
Part-A EMERGENCY Whether emergency exit
MANAGEMENT 4.07 available and direction of
SYSTEMS the same displayed?
Part-A EMERGENCY Whether any Mock Drill
MANAGEMENT for Disaster Management
SYSTEMS 4.08 Plan organised, actions
taken on shortcomings and
plan updated.
Part-A EMERGENCY Whether proper
MANAGEMENT communication system
SYSTEMS exists in the location
4.09
including P&T
telephones/PA paging
system/walkie-talkie etc.
Part-A EMERGENCY Whether personal
MANAGEMENT protective equipment are
4.10
SYSTEMS available at the location
(See Annex.IV)

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Part-A EMERGENCY Whether adequate security

MANAGEMENT arrangements/records are
SYSTEMS 4.11 available at the location to
identify a person/vehicles
entering the premises.
Part-A EMERGENCY Whether identity cards are
MANAGEMENT issued and worn by
SYSTEMS employees, visitors and
4.12
contractors personnel for
admission to restricted
areas.
Part-A EMERGENCY Whether metal detectors
MANAGEMENT 4.13 and mirror trolleys are
SYSTEMS available and used.
Part-A EMERGENCY Whether the boundary
MANAGEMENT wall/compound wall is as
4.14
SYSTEMS per MOHA/BPE/Corp.
Security guidelines.
Part-A EMERGENCY Whether any minor/major
MANAGEMENT accident had occurred in
4.15
SYSTEMS last five years and records
available.
Part-A EMERGENCY Whether remedial actions
MANAGEMENT are taken to prevent
4.16
SYSTEMS recurrence of the
accidents.
Part-A EMERGENCY Whether information of
MANAGEMENT accidents/ near misses are
SYSTEMS 4.17
disseminated to all
concerned.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Part-A SAFETY AUDITS Whether following audits

are conducted - (Check
records for last five years)
a) Internal safety audit as
per OISD 145 (Refer
Annexure)
- i) Frequency
- ii) Formation of team
- iii) Total No. of
recomme
- iv) No. of
recommendations
implemented.ndations
- v) Status of
5.01 implementation on balance
points (Refer Annex V)
b) Electrical safety audits
- i) Frequency (minimum
once in three Years)
- ii) Formation of
team/party
- iii) Total No. of
recommendations
- iv)No. of
recommendations
implemented
- v)Status of
implementation on balance
points (Ref.Annex.VI)
Part-A SAFETY AUDITS Whether self-safety audit
5.02
by location is conducted
Part-A LAYOUT & Whether updated and CCE
FACILITIES approved drawing showing
6.01
all facilities is available.
(Ref.Annex.II)
Part-A LAYOUT & Whether inter-distances
FACILITIES 6.02
are as per OISD 235.
Part-A LAYOUT & Whether updated drawing
FACILITIES showing fire hydrant
6.03
system/firefighting
equipment is available.
Part-A LAYOUT &
FACILITIES Whether updated P&I
6.04 diagram available for
product pipelines.

Part-A OPERATIONAL Whether records for

ACTIVITIES 7.01 checks for T/T as per
checklist are available.
Part-A OPERATIONAL Whether work permits are
ACTIVITIES issued as per OISD 105
7.02
and job completion details
are recorded

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Part-A OPERATIONAL Whether logbooks are

ACTIVITIES 7.03 available for fire pumps,
DG sets.
Part-A MAINTENANCE &
INSPECTION Whether maintenance
SYSTEMS schedule for following
equipment maintained and
followed: -
a) Pumps
8.01
b) Diesel Engines
c) Storage Tanks
d) Pipes
e) Valves/fitting
f) Hoses.

Part-A MAINTENANCE & Whether pressure

INSPECTION gauges/other gauges are
SYSTEMS 8.02 checked regularly with
master gauge and record
available.
Part-A MAINTENANCE & Whether history cards for
INSPECTION 8.03 all equipment and storage
SYSTEMS tanks are available.
Part-A MAINTENANCE & Whether preventive
INSPECTION maintenance is carried out
SYSTEMS 8.04 departmentally/ original
manufacturers/other
vendors.
Part-A MAINTENANCE & Whether tanks are cleaned
INSPECTION 8.05 as per Industry QC
SYSTEMS manual.
Part-A MAINTENANCE & Whether periodical
INSPECTION inspections,
SYSTEMS maintenance/hydro testing
8.06
of fire extinguishers are
carried out and proper
records maintained.
Part-A ELECTRICAL Whether approval is
SYSTEMS 9.01 available for DG set
Installation.
Part-A ELECTRICAL Whether drawings
SYSTEMS showing earthing
9.02
grids/electrical cable
routes are available.
Part-A ELECTRICAL Whether test records for
SYSTEMS earth resistance for tanks,
9.03
pumps, electrical
installations are available.
Part-A ELECTRICAL Whether dielectric strength
SYSTEMS of transformer oil is
9.04
carried out and records
available.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Part-A LICENCES & Whether following

DOCUMENTATIONS licenses/approvals as
applicable are available:
- CCE license -Factory
license
10.01 - Environment Pollution
Consent for
i) Air Pollution
ii) Water pollution-
Weights & Measures
Approval / certificates.
Part-A LICENCES & Whether following
DOCUMENTATIONS manuals/standards, as
applicable, are available at
site (printed or in soft
form):
1) Petroleum Acts & Rules
2)Pollution Control Acts &
Rules
3)Weights & Measure
10.02
Act/Rules
4)Motor Vehicle Act
5)Aviation Operations
manual
6)HS&E manual
7)DGCA approved QC
Manual for Aviation
product
8)OISD Standards
Part-A LICENCES & Equipment Manufacturer’s
DOCUMENTATIONS Manual-
10.03
1) DG sets
2) Fire engines
Part-A STATUS ON
IMPLEMENTATION OF
RECOMMENDATIONS 11.01 Date of last Audit
OF EXTERNAL
SAFETY AUDIT.
Part-A STATUS ON
IMPLEMENTATION OF Whether implementation
RECOMMENDATIONS of external safety audits
11.02
OF EXTERNAL recommendations are
SAFETY AUDIT. monitored.
Part-A STATUS ON
IMPLEMENTATION OF Total Number of
RECOMMENDATIONS recommendations. Status
11.03
OF EXTERNAL of pending points of last
SAFETY AUDIT. external safety audit.
Part-A STATUS ON
IMPLEMENTATION OF
RECOMMENDATIONS No. of recommendations
11.04
OF EXTERNAL implemented.
SAFETY AUDIT.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Part-A STATUS ON No. of balance

IMPLEMENTATION OF recommendations :(Ref.
RECOMMENDATIONS 11.05 Annexure VII)
OF EXTERNAL a) Under implementation
SAFETY AUDIT. b) Action not initiated
Part-B TANK FARM Whether Dyke/fire walls
12.01 meet OISD – 118/CCE
regulations?
PART B TANK FARM Whether motorable roads
are available around the
tank farm for movement
12.02
for fire tenders for AFS
with more than 5000 KL
AG storage tanks?
PART B TANK FARM
Whether house keeping in
12.03 the area is satisfactory and
it is free of dry vegetation.
PART B TANK FARM Whether drains are
12.04 provided in the tank farm
& kept clean?
PART B TANK FARM Whether drainage from
A/G tank farm with more
than 1000 KL AG tanks, is
12.05 routed through oil water
separator and isolation
valve provided at tank
farm exist?
PART B TANK FARM Whether important data
like tank capacity, product,
due date of cleaning/
12.06
painting, ref. height and
safe filling height are
painted on tank?
PART B TANK FARM Whether A/G tanks are
provided with
12.07
circumferential railings on
roof with toe guards?
PART B TANK FARM Whether any depression
due to tank settlement
12.08 observed in A/G vertical
tanks on the tank pad along
the circumference?
PART B TANK FARM Any visible leaks/sweating
12.09 observed on the A/G
tanks?
PART B TANK FARM
Any corrosion observed on
12.10 annular/shell/roof plates of
A/G tanks & structures?
PART B TANK FARM Whether goose neck type
vent connections are
12.11
provided with suitable wire
mesh?

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PART B TANK FARM Whether any blending of

WMM product resorted
12.12 to? If so, what are the
procedures & safety
precautions taken?
PART B TANK FARM Whether cross checking of
auto level gauge is done
through manual gauge,
while the tanks are under
12.13
operation for tanks
provided at AFSs with
more than 1000 KL A/G
storage tanks .
PART B TANK FARM Check condition of
12.14 earthing strips and pits for
all tanks.
PART B TANK FARM Provision of double valve
12.15 segregation on inlet/outlet
of A/G tanks.
PART B TANK FARM Any water logging
12.16 observed on fixed roof of
AG tanks
PART B TANK FARM Whether the ladders,
12.17 stairways/cat walk are in
good condition?
PART B TANK FARM Whether expansion lines
are provided on pipelines
12.18
& are connected to A/G
tanks properly.
PART B TANK FARM Whether sprinkler system
is provided for A/G tanks
12.19 (more than 30 m dia) as
per OISD-235.

PART B TANK FARM Whether foam systems

(trolley mounted) are
12.20 provided as per OISD 235
for A/G tanks (more than
18m dia).
PART B TANK FARM Whether adequate
coverage by
hydrant/monitor is
12.21
provided to A/G tank
farms with more than 1000
KL capacity.
PART B TANK FARM If location receives product
through pipeline please
12.22 check condition of
pipelines and maintenance
procedures.
PART B TANK FARM Whether refuelling hoses
12.23 are pressure tested &
record maintained.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

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STORAGE, HANDLING, REFUELLING AND FIRE FIGHTING AT AVIATION
FUELLING STATIONS

PART B TANK FARM MOVs provided are in

proper working conditions
12.24
with shut off facilities in
control room.
PART B PUMP HOUSE Whether the pumps details
13.01 are displayed with number
?
PART B PUMP HOUSE Whether delivery to
suction bypass line/re-
13.02 circulation line to storage
tank has been provided for
HRS locations?
PART B PUMP HOUSE Whether adequate
13.03 ventilation exists (in case
of covered pump house) ?
PART B PUMP HOUSE Whether sump is provided
13.04 to collect spills & is kept
clean?
PART B PUMP HOUSE Whether double earthings
13.05
are provided for motor.
PART B PUMP HOUSE Whether all electrical
fitting/motors are
13.06
flameproof, properly
installed.
PART B PUMP HOUSE Whether coupling guards
13.07 are provided for
pump/motor.
PART B UNLOADING/TOPPING Whether all the drains are
UP POINT. routed to OWS for AFS
14.01
with more than 1000 KL
A/G capacity storage.
PART B UNLOADING/TOPPING Whether unloading hoses
UP POINT. 14.02 are having proper electric
continuity.
PART B UNLOADING/TOPPING Whether proper earthing is
UP POINT. 14.03 provided to Topping
up/unloading structure.
PART B UNLOADING/TOPPING Whether earthing as well
UP POINT. as bonding is ensured
14.04
during loading/unloading
operation
PART B UNLOADING/TOPPING Whether safety operating
UP POINT. 14.05
instructions are displayed.
PART B UNLOADING/TOPPING Whether TT unlaoding
UP POINT. section is adequately
14.06 covered by hydrant system
for AFSs with more than
1000KL A/G storage.
PART B UNLOADING/TOPPING Whether safe operating
UP POINT. practices are followed for
14.07
topping up/unlaoding of
product.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

OISD – STD – 235 Page No. 118

STORAGE, HANDLING, REFUELLING AND FIRE FIGHTING AT AVIATION
FUELLING STATIONS

PART B UNLOADING/TOPPING Whether proper colour

UP POINT. 14.08 coding as per QC manual
is provided.
PART B ELECTRICAL SYSTEM Whether all electrical
fittings, lighting provisions
15.01
etc. are as per hazard area
classification.
PART B ELECTRICAL SYSTEM Whether all earthing
connections/pits are
15.02
provided as per
IS:3043/Oil Co. spec.
PART B ELECTRICAL SYSTEM Whether separate earthing
15.03 is provided for lightening
arresters, if provided
PART B ELECTRICAL SYSTEM Whether fencing to
transformer yard is
15.04
provided with efficient
earthing.
PART B ELECTRICAL SYSTEM Whether suitable breaker
system is provided to
15.05
break in full load
condition.
PART B ELECTRICAL SYSTEM Whether clear spacing is
15.06 provided in front and rear
of the main panels.
PART B ELECTRICAL SYSTEM Whether rubber mats of
adequate rating with ISI
15.07 marking are provided in
front of and rear of the
main panels.
PART B ELECTRICAL SYSTEM Whether proper ventilation
15.08 is provided for the room
for battery charging.
PART B ELECTRICAL SYSTEM Whether the cable ends in
switch boards/bus
bars/motors and other
15.09
equipment are provided
with lugs and properly
secured.
PART B ELECTRICAL SYSTEM Whether emergency lights
are provided in sub station
15.10
and switch room, DG set
room.
PART B ELECTRICAL SYSTEM Whether proper
15.11 identification of cables and
switches is provided.
PART B ELECTRICAL SYSTEM Whether proper inter-
locking between two
different supply sources
15.12
has been provided,
wherever 2 sources are
available .
PART B ELECTRICAL SYSTEM Does the reservoir contain
sufficient transformer oil
15.13
for locations with
transformer?

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

OISD – STD – 235 Page No. 119

STORAGE, HANDLING, REFUELLING AND FIRE FIGHTING AT AVIATION
FUELLING STATIONS

PART B ELECTRICAL SYSTEM Provision of adequate

15.14 ventilation for transformer,
(if installed in door).
PART B ELECTRICAL SYSTEM Whether security is trained
15.15 for isolating the supply in
emergency.
PART B FIRE PROTECTION Whether fire water storage
SYSTEM 16.01 capacity is adequate as per
OISD-117 ( Annexure III )
PART B FIRE PROTECTION What are the sources of
16.02
SYSTEM water
PART B FIRE PROTECTION Whether pumps are
SYSTEM 16.03
installed as per OISD.
PART B FIRE PROTECTION Is main hydrant line,
SYSTEM 16.04 wherever provided, kept
under pressure?
PART B FIRE PROTECTION Whether the pumps are in
SYSTEM 16.05
auto or manual mode.
PART B FIRE PROTECTION Is logbook available for
SYSTEM operation and maintenance
16.06
Of FW pump.
PART B FIRE PROTECTION What are the types and
SYSTEM 16.07
quantity of foam available?
PART B FIRE PROTECTION What are the storage
SYSTEM 16.08 arrangements of foam and
its accessibility?
PART B FIRE PROTECTION Whether hydrant system is
SYSTEM 16.09 laid properly to avoid
corrosion.
PART B FIRE PROTECTION Are monitors/ hydrants
SYSTEM properly distributed in
16.10 critical areas and all
facilities covered & are
easily operable.
PART B FIRE PROTECTION Check the pressure at
16.11
SYSTEM farthest point.
PART B FIRE PROTECTION Are portable extinguishers
SYSTEM meeting OISD
16.12 requirements? Are they
BIS approved (Refer
Annexure IV)
PART B FIRE PROTECTION Whether wheeled
SYSTEM equipment are placed as
16.13
per OISD standards. (Refer
Annex. IV)
PART B FIRE PROTECTION Whether hoses, nozzles
SYSTEM and accessories are
16.14 available as per OISD
standards. (Refer
Annexure IV)

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

OISD – STD – 235 Page No. 120

STORAGE, HANDLING, REFUELLING AND FIRE FIGHTING AT AVIATION
FUELLING STATIONS

PART B FIRE PROTECTION Whether adequate

SYSTEM cartridges and DCP
16.15
available in the store (10%
of the total extinguishers).
PART B FIRE PROTECTION Whether hand operated /
SYSTEM electric fix siren (3km
16.16
range) is provided at
strategic locations.
PART B GATE SECURITY Whether security checks
17.01 are carried out at the main
gate for matches/lighters.
PART B GATE SECURITY Whether the movement of
tank trucks is properly
17.02 regulated at the main gate
for easy escape during
emergency.
PART B GATE SECURITY Whether NO SMOKING
signs, Explosives License
17.03
Number, Speed Limit are
displayed at the main gate.
PART B GATE SECURITY Whether metal detectors
and mirror trolleys are
17.04
provided and are being
regularly used.
PART B GATE SECURITY Whether important
telephone numbers at the
17.05
main gate/office are
displayed.
PART B GATE SECURITY Whether First Aid boxes
17.06 with requisite medicines
are provided.
PART B GATE SECURITY Whether telephone is
provided to watch and
17.07
ward for communication
after shift hours.
PART B LABORATORY Whether fire extinguishers
18.01
are adequately positioned.
PART B LABORATORY Whether important
18.02 instructions, emergency
procedures displayed.
PART B LABORATORY Whether ELCB/ MCB
18.03 installed in the main power
switchboard.
PART B LABORATORY Whether the switches/plug
sockets for various
18.04 equipment safe and should
be provided with metal
cladding.
PART B STORE/WAREHOUSE Materials are stacked
19.01 properly in the warehouse
for proper identification.
PART C REFUELLING Whether valid
OPERATIONS 20.01 explosive/PESO licences
available for refuellers

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/1

OISD – STD – 235 Page No. 121

STORAGE, HANDLING, REFUELLING AND FIRE FIGHTING AT AVIATION
FUELLING STATIONS

PART C REFUELLING Each refuellers/hydrant

OPERATIONS dispensers are equipped
with 2 nos. DCP
20.02
extinguishers and 1 CO2
type extinguisher inside
cabin.
PART C REFUELLING Soak pads are available in
OPERATIONS the refuellers/ hydrant
20.03
dispensers as oil spill
recovery kit.
PART C REFUELLING Whether spark arrestors
OPERATIONS are provided on
20.04 refuellers/dispensers and
are IS marked, unless
exempted.
PART C REFUELLING Continuity maintained for
OPERATIONS bonding wire in
20.05
refuellers/hydrant
dispensers.
PART C REFUELLING Deadman control of
OPERATIONS refuellers/hydrant
20.06
dispensers are in working
conditions.
PART C REFUELLING
OPERATIONS Whether SOP is followed
20.07
during refuelling.

PART C REFUELLING Whether safety devices

OPERATIONS like PCV, PV vents on top
of refuellers, brake
20.08
interlock of
refuellers/dispensers, etc
are in working condition.
PART C REFUELLING
Cathodic protection of
OPERATIONS
HRS PL is in working
20.09
condition and records
maintained
PART C REFUELLING Emergency shutdown
OPERATIONS (ESD) points are located
20.10 on the tarmac in accessible
position and in sealed
condition.
PART C REFUELLING The hydrant pits are clean,
OPERATIONS free of water and fuel with
20.11
with pit covers and
isolation valves.
PART C REFUELLING The high and low points on
OPERATIONS the hydrant line are clean,
20.12
free of water/fuel with
arrangement for sampling.
PART C PACKED STORAGE
Whether Class A product
21.01 stored in barrels are as per
manualized instructions.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”